Chemical recycling of waste plastic materials using improved solvolysis catalysts

Abstract

A chemical recycling facility for the treatment of mixed waste plastics is provided. Such a facility has the capacity to process mixed plastic waste streams and utilizes various recycling units, such as a solvolysis unit, a pyrolysis unit, a cracking unit, a partial oxidation gasification unit, an energy recovery unit, and a solidification unit. Streams from one or more of these individual units may be used as feed streams to one or more of the other units, thereby maximizing the recovery of valuable chemical components and minimizing unusable waste streams.

Description

[Background technology]

[0001]

[0001] Waste, especially non-biodegradable waste, can have adverse effects on the environment if it is disposed of in landfills after a single use. Therefore, from an environmental standpoint, it is desirable to recycle as much waste as possible. However, there are still low-value waste flows that are nearly impossible or economically unfeasible to recycle using conventional recycling technologies. Furthermore, some conventional recycling methods generate waste flows that themselves cannot be economically recovered or recycled, resulting in further waste flows that must be disposed of or processed by other means.

[0002]

[0002] Solvolysis is used to break down plastics, such as polyethylene terephthalate (PET), into their constituent monomers. This decomposition can be carried out using various solvents, such as water, or various glycols, amines, or alcohols. In such a process, the regenerated components ethylene glycol and dimethyl terephthalate are obtained, but several byproduct streams are also obtained, which include mixtures containing useful organic compounds and byproducts that are difficult to remove. Therefore, it is difficult and costly to regenerate and / or recover specific components from these byproduct streams.

[0003]

[0003] Several catalysts are known for solvolysis (particularly methanol decomposition) reactions. However, such conventional catalysts do not appear to be efficient for treating waste plastics compared to treating purer feed streams. As a result, using conventional catalysts to treat mixed waste plastics produces various impurities, reducing the overall efficiency of the reaction, particularly in terms of the amount of solvent required to produce one pound (or one kilogram) of terephthalate product. Many of the impurities from the solvolysis reaction end up in the byproduct stream, which is difficult to remove, and higher levels of impurities require more expense in the treatment process. [Overview of the Initiative]

[0004]

[0004] In one aspect, the present technology relates to a method for processing waste plastics, comprising the steps of (a) combining a stream of waste plastics, including polyethylene terephthalate (PET) and at least one non-PET plastic, with a solvent in a solvolysis tank to provide a stream that is mainly liquid; (b) adding a catalyst, including lithium, manganese, or a combination thereof, to the stream that is mainly liquid; and (c) depolymerizing at least a portion of the PET in a solvolysis reaction vessel to form a stream of main terephthalyl, main glycol, and at least one byproduct.

[0005]

[0005] In one aspect, the present technology relates to a method for processing waste plastics, comprising the steps of (a) mixing a stream of waste plastics, including polyethylene terephthalate (PET) and at least one non-PET plastic, with a solvent in a solvolysis dissolution tank to provide a stream that is mainly liquid; (b) passing at least a portion of the stream that is mainly liquid through a solvolysis reaction vessel; (c) adding a catalyst, including lithium, manganese, sodium, potassium, or a combination thereof, to the waste plastics, the solvent, or at least one of the stream that is mainly liquid; and (d) depolymerizing at least a portion of the PET in the solvolysis reaction vessel to form a stream of main terephthalyl, main glycol, and at least one byproduct.

[0006]

[0006] In one aspect, the present technology relates to a method for treating waste plastics, comprising the steps of (a) subjecting a stream of waste plastics containing polyethylene terephthalate (PET) to solvolysis in a solvolysis facility, wherein at least a portion of the solvolysis is carried out in the presence of at least one solvolysis catalyst including manganese, lithium, or a combination thereof, to produce a major glycol, a major terephthalyl, and at least one solvolysis byproduct; and (b) introducing at least a portion of the solvolysis byproduct into at least one of (i) a pyrolysis facility, (ii) a cracking facility, (iii) a partial oxidation (POX) gasification facility, (iv) an energy recovery facility, and (v) a liquefaction section.

[0007]

[0007] In one aspect, the present technology relates to a solvolysis process composition comprising polyethylene terephthalate (PET) and / or its decomposition products, at least one non-PET plastic and / or its decomposition products, a major solvent, and a catalyst comprising manganese and / or lithium. [Brief explanation of the drawing]

[0008] [Figure 1A]

[0008] Figure 1A is a block flow diagram showing the main processes of the chemical recycling process and facility for waste plastics according to an embodiment of the present technology. [Figure 1B]

[0009] Figure 1B is a block flow diagram showing the main processes and equipment for the chemical recycling of waste plastics, particularly additional aspects of the processes / equipment as shown in Figure 1A. [Figure 2]

[0010] Figure 2 is a block flow diagram showing the separation process and separation sections for separating mixed plastic waste according to an embodiment of this technology. [Figure 3]

[0011] Figure 3 is a schematic block flow diagram showing the main steps of the process and equipment for PET solvolysis according to an embodiment of this technology. [Figure 4]

[0012] Figure 4 is a block flow diagram showing the separation of light organic materials from the PET solvolysis equipment shown in Figure 3. [Figure 5]

[0013] Figure 5 is a block flow diagram that shows a portion of the chemical regeneration facility shown in Figure 1a, particularly highlighting the relationship between the liquefaction section and other equipment and processes according to this embodiment of the technology. [Figure 6]

[0014] Figure 6 is a block flow diagram showing an exemplary liquefaction section of Figure 5 according to an embodiment of this technology. [Figure 7]

[0015] Figure 7 is a block flow diagram showing the main steps of the pyrolysis process and equipment used to convert waste plastics into a pyrolysis product stream according to this technology. [Figure 8A]

[0016] Figure 8A is a block flow diagram showing the main processes of the integrated pyrolysis process and equipment and the cracking process and equipment according to an aspect of the present technology. [Figure 8B]

[0017] Figure 8B is a schematic diagram of a cracking furnace according to an aspect of the present technology. [Figure 9]

[0018] Figure 9 is a schematic diagram of a POx reaction vessel according to an aspect of the present technology. [Figure 10]

[0019] Figure 10 is a schematic diagram showing various definitions of the term "separation efficiency" used in this specification. [Figure 11]

[0020] Figure 11 is a graph showing the results of the methanolysis reaction of waste plastic materials using several different types of catalysts described in the examples, particularly the impurity and methanol-to-terephthalate ratio in each test. [Figure 12]

[0021] Figure 12 is a graph showing the results of the methanolysis reaction of waste plastic materials using several concentrations of the manganese catalyst described in the examples, particularly the impurity and methanol-to-terephthalate ratio in each test. [[ID=!24]] [Figure 13]

[0022] Figure 13 is a graph showing the results of the methanolysis reaction of waste plastic materials using the manganese catalyst described in the examples and varying the concentration of sodium hydroxide, particularly the impurity and methanol-to-terephthalate ratio in each test. Detailed Description of the Invention

[0009]

[0023] The inventors have discovered a catalyst system that produces less impurities and is efficient (as evidenced by a low methanol / terephthalate ratio). In particular, a catalyst system containing a catalyst comprising manganese and / or a lithium compound (alone or in combination with a base) promotes reactions with fewer impurities than conventional catalysts and may require less methanol per pond of terephthalate produced.

[0010]

[0024] When a series of numbers is shown, each number is modified in the same way as the first or last number in the series or text. For example, each number may be "at least", or "up to", or "below", and each number is in an "or" relationship. For example, "at least 10, 20, 30, 40, 50, 75% by weight..." means the same as "at least 10% by weight, or at least 20% by weight, or at least 30% by weight, or at least 40% by weight, or at least 50% by weight, or at least 75% by weight, etc.", "90% by weight or less, 85, 70, 60..." means the same as "90% by weight or less, or 85% by weight or less, or 70% by weight or less...", "at least 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight..." means the same as "at least 1% by weight, or at least 2% by weight, or at least 3% by weight...", and "at least 5, 10, 15, 20, and / or 99, 95, 90% by weight or less" means "at least 5% by weight, or at least 10% by weight, or at least 15% by weight, or at least 20% by weight, and / or 99% by weight or less, or 95% by weight or less, or 90% by weight or less...".

[0011]

[0025] Unless otherwise specified, all concentrations or amounts are on a weight basis. Chemical regeneration treatment facilities in general

[0026] Turning to FIGS. 1a and 1b here, the main steps of the chemical regeneration treatment process of waste plastics in the chemical regeneration treatment facility 10 are shown. Note that FIGS. 1a and 1b depict an exemplary aspect of the present technology. The specific configurations depicted in FIGS. 1a and 1b may be omitted, and / or additional configurations described elsewhere in this specification may be added to the systems depicted in FIGS. 1a and 1b.

[0012]

[0027] As shown in Figures 1a and 1b, these processes generally include at least one (or at least two or more) of the following: pretreatment process / equipment 20, solvolysis process / equipment 30, partial oxidation (POX) gasification process / equipment 50, pyrolysis process / equipment 60, cracking process / equipment 70, and energy recovery process / equipment 80. If necessary, in one embodiment or in combination with any embodiment described herein, these processes may also include one or more other processes, such as direct sale or use, landfill, separation, and solidification, one or more of which are represented by block 90 in Figures 1a and 1b. Although shown as including all of these processes or equipment, naturally, the chemical regeneration processes and equipment according to one or more embodiments of the Art may include at least two, three, four, five, or all of these processes / facilities in various combinations for the chemical regeneration of plastic waste, particularly mixed plastic waste. The chemical recycling processes and facilities described herein can be used to convert waste plastics into recycled component products or chemical intermediates used to form various end-use materials. The waste plastics supplied to the chemical recycling facilities / processes may be mixed plastic waste (MPW), pre-sorted waste plastics, and / or pre-treated waste plastics.

[0013]

[0028] As used herein, the term "chemical recycling" means a waste plastic recycling process that includes steps to convert waste plastic polymers into low molecular weight polymers, oligomers, monomers, and / or nonpolymer molecules (e.g., hydrogen and carbon monoxide) that are useful in themselves and / or useful as raw materials in one or more other chemical production processes. A "chemical recycling facility" is a facility that produces recycled component products by chemical recycling of waste plastics. As used herein, the terms "recycled component" and "recycled component" mean a composition that is directly and / or indirectly derived from waste plastics, or that includes such a composition.

[0014]

[0029] As used herein, the term "directly derived" means having at least one physical component derived from waste plastics, and "indirectly derived" means having a specified recycled component that i) arises from waste plastics but ii) does not have a physical component derived from waste plastics.

[0015]

[0030] Chemical recycling facilities are not mechanical recycling facilities. As used herein, the terms “mechanical recycling” and “physical recycling” mean recycling processes that include the steps of melting waste plastics and molding the molten plastics into new intermediate products (e.g., pellets or sheets) and / or new final products (e.g., bottles). In general, mechanical recycling does not essentially alter the chemical structure of the plastics being recycled. In one embodiment or in combination with any embodiment described herein, the chemical recycling facilities described herein may be configured to receive and process waste streams from mechanical recycling facilities and / or waste streams that cannot generally be processed by mechanical recycling facilities.

[0016]

[0031] In this specification, they are described as part of a single chemical regeneration facility, but naturally, one or more of the pretreatment equipment 20, solvolysis equipment 30, pyrolysis equipment 60, cracking equipment 70, partial oxidation (POX) gasification equipment 50, energy recovery equipment 80, or other equipment 90 such as solidification or separation may be located in different geographical locations and / or operated by different entities. Each of the pretreatment equipment 20, solvolysis equipment 30, pyrolysis equipment 60, cracking equipment 70, partial oxidation (POX) gasification equipment 50, energy recovery equipment 80, or other equipment 90 may be operated by the same entity, but one or more of the pretreatment equipment 20, solvolysis equipment 30, pyrolysis equipment 60, cracking equipment 70, partial oxidation (POX) gasification equipment 50, energy recovery equipment 80, or one or more other equipment 90 such as separation or solidification may be operated by different entities.

[0017]

[0032] In one embodiment or in combination with any embodiment described herein, the chemical recycling facility 10 may be a commercial-scale facility capable of processing a substantial amount of mixed plastic waste. As used herein, “commercial-scale facility” means a facility having an average annual supply of at least 500 pounds per hour on average over a year. The average supply to the chemical recycling facility (or any one of the pretreatment equipment 20, solvolysis equipment 30, pyrolysis equipment 60, cracking equipment 70, POX gasification equipment 50, energy recovery equipment 80, and any other equipment 90) is at least 750 pounds per hour, at least 1,000 pounds, at least 1,500 pounds, at least 2,000 pounds, at least 2,500 pounds, at least 3,000 pounds, at least 3,500 pounds, at least 4,000 pounds, at least 4,500 pounds, at least 5,000 pounds, at least 5,500 pounds, at least 6,000 pounds, at least 6,500 pounds, at least 7,500 pounds. The amount may be pounds, at least 10,000 pounds, at least 12,500 pounds, at least 15,000 pounds, at least 17,500 pounds, at least 20,000 pounds, at least 22,500 pounds, at least 25,000 pounds, at least 27,500 pounds, at least 30,000 pounds, or at least 32,500 pounds, and / or not more than 1 million pounds per hour, not more than 750,000 pounds, not more than 500,000 pounds, not more than 450,000 pounds, not more than 400,000 pounds, not more than 350,000 pounds, not more than 300,000 pounds, not more than 250,000 pounds, not more than 200,000 pounds, not more than 150,000 pounds, not more than 100,000 pounds, not more than 75,000 pounds, not more than 50,000 pounds, or not more than 40,000 pounds. If the facility includes two or more supply flows, the average annual supply is determined based on the total weight of the supply flows.

[0018]

[0033] Furthermore, naturally, each of the pretreatment equipment 20, solvolysis equipment 30, pyrolysis equipment 60, cracking equipment 70, POX gasification equipment 50, energy recovery equipment 80, and other equipment 90 may include multiple devices operating in series or in parallel. For example, pyrolysis equipment 60 may include multiple pyrolysis reaction vessels / devices operating in parallel, each receiving feed containing waste plastics. If the equipment consists of multiple individual devices, the average annual feed to the equipment is calculated as the sum of the average annual feeds to all common devices within that equipment.

[0019]

[0034] Furthermore, in one embodiment or in combination with any embodiment described herein, the chemical regeneration facility 10 (i.e., any one of the pretreatment equipment 20, solvolysis equipment 30, pyrolysis equipment 60, cracking equipment 70, POX gasification equipment 50, energy recovery equipment 80, and other equipment 90) can be operated continuously. In addition, or instead, at least a portion of the chemical regeneration facility 10 (i.e., any one of the pretreatment equipment 20, solvolysis equipment 30, pyrolysis equipment 60, cracking equipment 70, POX gasification equipment 50, energy recovery equipment 80, and other equipment 90) may be operated in batch or semi-batch. In some cases, the equipment may include multiple tanks between multiple parts of a single piece of equipment or between two or more different pieces of equipment to manage inventory and ensure a consistent flow rate to each piece of equipment or part thereof.

[0020]

[0035] Furthermore, two or more of the equipment shown in Figures 1a and 1b may be jointly installed with each other. In one embodiment or in combination with any embodiment described herein, at least two, at least three, at least four, at least five, at least six, or all of the equipment may be jointly installed. As used herein, “jointly installed” means equipment in which at least a portion of the processing flow and / or supporting equipment or services are shared between the two pieces of equipment. If two or more facilities shown in Figures 1a and 1b are jointly installed, these facilities must satisfy at least one of the following criteria (i) to (v): (i) the facilities share at least one non-residential utility service; (ii) the facilities share at least one service group; (iii) the facilities are owned and / or operated by parties sharing at least one site boundary; (iv) the facilities are connected by at least one conduit configured to transport at least one treatment substance (e.g., solids, liquids, and / or gases supplied to, used in, or produced in the facilities) from one facility to another; and (v) the facilities are within 40 miles, 35 miles, 30 miles, 20 miles, 15 miles, 12 miles, 10 miles, 8 miles, 5 miles, 2 miles, or 1 mile from each other, measured from the geographical center. At least one, at least two, at least three, at least four, or all of the above criteria (i) to (v) may be met.

[0021]

[0036] Regarding criterion (i), examples of appropriate utility services include, but are not limited to, steam systems (heat and power supply and distribution systems), cooling water systems, heat transfer fluid systems, plant or instrumentation air systems, nitrogen systems, hydrogen systems, non-residential power generation and distribution (including distribution of 8000V or higher), non-residential wastewater / sewage systems, storage facilities, transport lines, lighting systems, and combinations thereof.

[0022]

[0037] With respect to criterion (ii), examples of service groups and facilities include, but are not limited to, emergency medical personnel (fire and / or medical), third-party contractors, national or local government supervisory groups, and combinations thereof. Government supervisory groups may include, for example, regulatory or environmental agencies, as well as municipal and tax authorities at the city, county, and state levels.

[0023]

[0038] With respect to criterion (iii), the boundary may be, for example, a fence line, a property boundary, a gate, or a boundary common to at least one boundary of land or facilities owned by a third party.

[0039] With respect to criterion (iv), the conduit may be a fluid conduit for transporting gases, liquids, solid / liquid mixtures (e.g., slurries), solid / gas mixtures (e.g., pneumatic transport), solid / liquid / gas mixtures, or solids (e.g., belt transport). In some cases, two devices may share one or more conduits selected from the above list. Fluid conduits may be used to transport process flows or utilities between two devices. For example, the outlet of one device (e.g., solvolysis device 30) may be fluidly connected to the inlet of another device (e.g., POX gasification device 50) via a conduit. In some cases, an intermediate storage system may be provided for materials transported in the conduit between the outlet of one device and the inlet of another device. The intermediate storage system may include, for example, one or more tanks, containers (open or closed), buildings, or containers configured to store materials transported by the conduit. In some cases, the amount of intermediate storage between the outlet of one facility and the inlet of another facility may be within 90 days, 75 days, 60 days, 40 days, 30 days, 25 days, 20 days, 15 days, 10 days, 5 days, 2 days, or 1 day.

[0024]

[0040] Returning to Figures 1a and 1b, a waste plastic stream 100, which may be mixed plastic waste (MPW), may be introduced into the chemical recycling facility 10. As used herein, the terms “waste plastic” and “plastic waste” mean used, scrap, and / or waste plastic material, such as plastic material that is generally sent to landfills. Other examples of waste plastic (or plastic waste) include used, scrap, and / or waste plastic material that is typically sent to incinerators. The waste plastic stream 100 supplied to the chemical recycling facility 10 may include untreated or partially treated waste plastic. As used herein, the term “untreated waste plastic” means waste plastic that has not been subjected to automated or mechanized sorting, washing, or crushing. Examples of untreated waste plastic include waste plastic collected from roadside plastic collection containers in homes or community-shared plastic collection containers. As used herein, the term “partially treated waste plastic” means waste plastic that has been subjected to at least one automated or mechanized sorting, washing, crushing step or process. Partially processed waste plastics may be generated, for example, from a municipal recycling facility (MRF) or a recycling company. When partially processed waste plastics are provided to a chemical recycling facility 10, one or more pretreatment steps may be omitted. The waste plastics may include at least one of post-industrial (or pre-consumer) plastics and / or post-consumer plastics.

[0025]

[0041] As used herein, the terms “mixed plastic waste” and “MPW” mean a mixture of at least two types of waste plastics, including but not limited to the following types of waste plastics: polyethylene terephthalate (PET), one or more polyolefins (PO), and polyvinyl chloride (PVC). In one embodiment or in combination with any embodiment described herein, MPW contains at least two different types of plastics. Each type of plastic is present in an amount of at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, or at least 20% by weight, based on the total weight of plastics in the MPW.

[0026]

[0042] In one embodiment or in combination with any embodiment described herein, the MPW contains, on a basis of the total weight of the plastics in the MPW, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of PET, and / or at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, or at least 20% by weight of PO. In one or more embodiments, the MPW may also contain small amounts of one or more plastic components other than PET and PO (and optionally PVC) in total, based on the total weight of the plastics in the MPW, less than 50% by weight, less than 45% by weight, less than 40% by weight, less than 35% by weight, less than 30% by weight, less than 25% by weight, less than 20% by weight, less than 15% by weight, less than 10% by weight, less than 5% by weight, less than 2% by weight, or less than 1% by weight.

[0027]

[0043] In one embodiment or in combination with any embodiment described herein, the MPW contains at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight, based on the total weight of the flow. Alternatively, or in addition to the above, MPW contains PET of 99.9% by weight or less, 99% by weight or less, 97% by weight or less, 92% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, or 5% by weight or less, based on the total weight of the flow.

[0028]

[0044] MPW flow may contain non-PET components in amounts of at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, or at least 35% by weight, and / or 80% or less by weight, 75% or less by weight, 70% or less by weight, 65% or less by weight, 60% or less by weight, 55% or less by weight, 50% or less by weight, 45% or less by weight, 40% or less by weight, 35% or less by weight, 30% or less by weight, 25% or less by weight, 20% or less by weight, 15% or less by weight, 10% or less by weight, or 7% or less by weight, based on the total weight of the flow. Non-PET components may be present in amounts between 0.1 and 50% by weight, 1 and 20% by weight, or 2 and 10% by weight, based on the total weight of the flow. Examples of such non-PET components include, but are not limited to, iron and non-ferrous metals, inert substances (rocks, glass, sand, etc.), substances inert to plastics (titanium dioxide, silicon dioxide, etc.), olefins, adhesives, compatibilizers, biological sludge, cellulose-based materials (corrugated cardboard, paper, etc.), and combinations thereof.

[0029]

[0045] In one embodiment or in combination with any embodiment described herein, all or part of the MPW may include municipal waste or municipal waste. The municipal waste portion of the MPW may include PET in amounts of, for example, 45-95% by weight, 50-90% by weight, or 55-85% by weight, based on the total weight of the municipal waste flow (or part of the flow).

[0030]

[0046] In one embodiment or in combination with any embodiment described herein, all or part of the MPW may be derived from municipal recycling facilities (MRF) and may contain PET in amounts of, for example, 65–99.9% by weight, 70–99% by weight, or 80–97% by weight, based on the total weight of the flow. Such non-PET components in the flow may contain other plastics in amounts of, for example, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 7% by weight, or at least 10% by weight, and / or 25% by weight or less, 22% by weight or less, 20% by weight or less, 15% by weight or less, 12% by weight or less, or 10% by weight or less, based on the total weight of the flow, or may be present in amounts ranging from 1–22% by weight, 2–15% by weight, or 5–12% by weight. In one embodiment or in combination with any embodiment described herein, the non-PET component may include other plastics in amounts ranging from 2 to 35% by weight, 5 to 30% by weight, or 10 to 25% by weight, on a gross weight basis of the flow, particularly if the MPW includes colored sorting plastics.

[0031]

[0047] In one embodiment or in combination with any embodiment described herein, all or part of the MPW may be derived from a recycling facility and may contain PET in amounts of, for example, 85–99.9% by weight, 90–99.9% by weight, or 95–99% by weight, based on the total weight of the flow. The non-PET component in such a flow may contain other plastics in amounts of, for example, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 7% by weight, or at least 10% by weight, and / or 25% by weight or less, 22% by weight or less, 20% by weight or less, 15% by weight or less, 12% by weight or less, or 10% by weight or less, based on the total weight of the flow, or may be present in amounts ranging from 1–22% by weight, 2–15% by weight, or 5–12% by weight, based on the total weight of the flow.

[0032]

[0048] As used herein, the term “plastic” may encompass any organic synthetic polymer that is solid at 25°C and 1 atm. In one embodiment or in combination with any embodiment described herein, the polymer may have a number average molecular weight (Mn) of at least 75 daltons, or at least 100 daltons, or at least 125 daltons, or at least 150 daltons, or at least 300 daltons, or at least 500 daltons, or at least 1,000 daltons, or at least 5,000 daltons, or at least 10,000 daltons, or at least 20,000 daltons, or at least 30,000 daltons, or at least 50,000 daltons, or at least 70,000 daltons, or at least 90,000 daltons, or at least 100,000 daltons, or at least 130,000 daltons. The weight-average molecular weight (Mw) of this polymer may be at least 300 daltons, or at least 500 daltons, or at least 1,000 daltons, or at least 5,000 daltons, or at least 10,000 daltons, or at least 20,000 daltons, or at least 30,000 daltons, or at least 50,000 daltons, or at least 70,000 daltons, or at least 90,000 daltons, or at least 100,000 daltons, or at least 130,000 daltons, or at least 150,000 daltons, or at least 300,000 daltons.

[0033]

[0049] Examples of suitable plastics include, but are not limited to, aromatic and aliphatic polyesters, polyolefins, polyvinyl chloride (PVC), polystyrene, polytetrafluoroethylene, acrylobutadiene styrene (ABS), cellulose-based materials, epoxides, polyamides, phenolic resins, polyacetals, polycarbonates, polyphenylene alloys, polymethyl methacrylate, styrene polymers, polyurethanes, vinyl polymers, styreneacrylonitrile, thermoplastic elastomers other than tire materials, urea-containing polymers, and melamine.

[0034]

[0050] Examples of polyesters include those having repeating aromatic or cyclic units, such as those having repeating terephthalate, isophthalate, or naphthalate units, specifically PET, modified PET, PEN, and those containing flunacate repeating units. Polyethylene terephthalate (PET) is also an example of a suitable polyester. As used herein, the terms "PET" or "polyethylene terephthalate" mean a homopolymer of polyethylene terephthalate, or polyethylene terephthalate modified with one or more acids and / or glycol modifiers, and / or polyethylene terephthalate containing residues or portions of substances other than ethylene glycol and terephthalic acid, such as isophthalic acid, 1,4-cyclohexanedicarboxylic acid, diethylene glycol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol (TMCD), cyclohexanedimethanol (CHDM), propylene glycol, isosorbide, 1,4-butanediol, 1,3-propyldiol, and / or neopentyl glycol (NPG).

[0035]

[0051] Furthermore, the definitions of the terms "PET" and "polyethylene terephthalate" include polyesters having terephthalate repeating units (whether or not they include ethylene glycol repeating units) and one or more residues or parts, such as TMCD, CHDM, propylene glycol, or NPG, isosorbide, 1,4-butanediol, 1,3-propanediol, and / or diethylene glycol, or combinations thereof. Examples of polymers having terephthalate repeating units include, but are not limited to, polypropylene terephthalate, polybutylene terephthalate, and their copolyesters. Examples of aliphatic polyesters include, but are not limited to, polylactic acid (PLA), polyglycolic acid, polycaprolactone, and polyethylene aziperte. Polymers may include, for example, mixed aliphatic-aromatic copolyesters containing mixed terephthalate / aziperte.

[0036]

[0052] In one embodiment or in combination with any embodiment described herein, the waste plastic may include at least one plastic having terephthalate repeating units, such plastic present in amounts of at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, or at least 30% by weight, and / or 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 2% by weight or less, or in amounts of 1 to 45% by weight, 2 to 40% by weight, or 5 to 40% by weight, based on the total weight of the flow. Similar amounts of copolyesters having multiple cyclohexanedimethanol moieties, 2,2,4,4-tetramethyl-1,3-cyclobutanediol moieties, or combinations thereof may also be present.

[0037]

[0053] In one embodiment or in combination with any embodiment described herein, the waste plastic may include at least one type of plastic having terephthalate repeating units, such plastic present in amounts of at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, or at least 90% by weight, and / or 99.9% by weight or less, 99% by weight or less, 97% by weight or less, 95% by weight or less, 90% by weight or less, or 85% by weight or less, or in amounts of 30 to 99.9% by weight, 50 to 99.9% by weight, or 75 to 99% by weight, based on the total weight of the flow.

[0038]

[0054] In one embodiment or in combination with any embodiment described herein, the waste plastic may contain terephthalate repeating units in amounts of at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, or at least 45% by weight, and / or 75% by weight or less, 72% by weight or less, 70% by weight or less, 60% by weight or less, or 65% by weight or less, or in amounts ranging from 1 to 75% by weight, 5 to 70% by weight, or 25 to 75% by weight.

[0039]

[0055] Specific examples of polyolefins include low-density polyethylene (LDPE), high-density polyethylene (HDPE), atactic polypropylene, isotactic polypropylene, syndiotactic polypropylene, crosslinked polyethylene, amorphous polyolefin, and copolymers of any one of the aforementioned polyolefins. Waste plastics may also include polymers containing linear low-density polyethylene (LLDPE), polymethylpentene, polybutene-1, and copolymers thereof. Waste plastics may also include flash-spun high-density polyethylene.

[0040]

[0056] The waste plastic may include thermoplastic polymers, thermosetting polymers, or combinations thereof. In one embodiment or in combination with any embodiment described herein, the waste plastic may include, on a basis of the total weight of the flow, one or more thermosetting polymers in amounts of at least 0.1% by weight, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, or at least 30% by weight, and / or 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 2% by weight or less, or on a basis of the total weight of the flow.

[0041]

[0057] Alternatively, or in addition, the waste plastic may contain, on a basis of the total weight of the flow, at least 0.1% by weight, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, or at least 30% by weight, and / or 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 2% by weight or less of cellulose material, or may be present in amounts ranging from 0.1 to 45% by weight, 1 to 40% by weight, or 2 to 15% by weight, on a basis of the total weight of the flow. Examples of cellulose material include recycled cellulose such as cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose propionate, cellulose butyrate, and viscose. Furthermore, the cellulose material may also include cellulose derivatives having an acyl substitution degree of less than 3, 2.9 or less, 2.8 or less, 2.7 or less, or 2.6 or less, and / or at least 1.7, at least 1.8, or at least 1.9, or 1.8 to 2.8, or 1.7 to 2.9, or 1.9 to 2.9.

[0042]

[0058] In one embodiment or in combination with any embodiment described herein, the waste plastic may include STYROFOAM® or expanded polystyrene.

[0059] The waste plastic may originate from one or more of several sources. In one embodiment or in combination with any embodiment described herein, the waste plastic may originate from plastic bottles, diapers, eyeglass frames, films, packaging materials, carpets (residential, commercial, and / or automotive), textiles (clothing and other fabrics), and combinations thereof.

[0043]

[0060] In one embodiment or in combination with any embodiment described herein, waste plastics (e.g., MPW) supplied to a chemical recycling facility may include one or more plastics having resin identification symbols 1 to 7 of the triangle with a chasing arrow as defined by SPI, or obtained from such resins. The waste plastics may also include one or more plastics that are not generally mechanically recycled. Examples of such plastics include, but are not limited to, plastics with resin identification symbol 3 (polyvinyl chloride), resin identification symbol 5 (polypropylene), resin identification symbol 6 (polystyrene), and / or resin identification symbol 7 (other). In one embodiment or in combination with any embodiment described herein, plastics having resin identification symbols 3 to 7 or at least one, at least two, at least three, at least four, at least five of 3, 5, 6, and 7, or a combination thereof, may be present in the waste plastics at a concentration of at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, and at least 12% by weight, based on the total weight of the plastics. It may be present in amounts of at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, or at least 40% by weight, and / or 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, or 35% by weight or less, or in amounts of 0.1 to 90% by weight, 1 to 75% by weight, or 2 to 50% by weight based on the total weight of the plastic.

[0044]

[0061] In one embodiment or in combination with any embodiment described herein, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, or at least 35% by weight, and / or 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, or 5% by weight or less of the total plastic components in the waste plastic supplied to a chemical recycling facility may include plastics that do not have resin identification symbols 3, 5, 6, and / or 7 (for example, plastics that are not classified). At least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 4% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, or at least 35% by weight, and / or 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, or 5% by weight or less of the total plastic components in the waste plastic supplied to the chemical recycling facility 10 may include plastics that do not have resin identification symbols 4 to 7, or such plastics may be in the range of 0.1 to 60% by weight, 1 to 55% by weight, or 2 to 45% by weight, based on the total weight of the plastic components.

[0045]

[0062] In one embodiment or in combination with any embodiment described herein, waste plastics (e.g., MPW) supplied to a chemical recycling facility may include plastics not classified under resin identification codes 3-7 or identification codes 3, 5, 6, or 7. The total amount of plastics not classified under resin identification codes 3-7 or identification codes 3, 5, 6, or 7 in the waste plastics is, on a basis of the total weight of plastics in the waste plastic stream, at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 4% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, and at least 50% by weight. It may be % by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, or at least 75% by weight, and / or 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, or 35% by weight or less, or it may be in the range of 0.1 to 95% by weight, 0.5 to 90% by weight, or 1 to 80% by weight based on the total weight of plastic in the waste plastic stream.

[0046]

[0063] In one embodiment or in combination with any embodiment described herein, the MPW comprises a plastic or plastic obtained therefrom having at least 1, at least 2, at least 3, or at least 4 types of resin identification symbols in an amount of at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight.

[0047]

[0064] In one embodiment or in combination with any embodiment described herein, MPW comprises a multicomponent polymer. As used herein, “multicomponent polymer” means an article and / or particles comprising at least one synthetic or natural polymer bonded, attached, or physically and / or chemically bonded to at least one other polymer and / or nonpolymeric solid. The polymer may be a synthetic polymer or plastic such as PET, olefin, and / or nylon. The nonpolymeric solid may be a metal such as aluminum, or other nonpolymeric solids described herein. The multicomponent polymer may also comprise metallized plastics.

[0048]

[0065] In one embodiment or in combination with any embodiment described herein, MPW comprises a multi-component plastic in the form of a multilayer polymer. As used herein, “multilayer polymer” means a multi-component polymer in which PET and at least one other polymer and / or non-polymeric solid are physically and / or chemically combined to form two or more physically distinct layers. A polymer or plastic is considered a multilayer polymer even if there are transition regions between two layers, such as those present in adhesive layers or co-extruded layers. Adhesives between two layers are not considered layers. A multilayer polymer may include a layer containing PET and one or more additional layers (at least one of which is a synthetic or natural polymer different from PET), or a polymer without ethylene tephthalate repeating units, or a polymer without alkylene tephthalate repeating units ("non-PET polymer layer"), or other non-polymeric solids.

[0049]

[0066] Examples of non-PET polymer layers include nylon, polylactic acid, polyolefin, polycarbonate, ethylene vinyl alcohol, polyvinyl alcohol, and / or other plastics or plastic films related to PET-containing articles and / or particles, as well as natural polymers such as whey protein. Multilayer polymers may include metal layers such as aluminum, provided that at least one additional polymer layer other than the PET layer is present. Each layer may be bonded by adhesive bonding or other means, physically adjacent (i.e., the article is pressed against the film), have increased adhesion (i.e., the plastics are heated and stick together), co-extruded into a plastic film, or otherwise attached to the PET-containing article. Multilayer polymers may include PET films bonded to articles containing other plastics in the same or similar manner. MPW may include PET bonded to a single physical phase and at least one other plastic, such as polyolefin (specifically, polypropylene), and / or synthetic or natural polymers. For example, MPW may include a heterogeneous mixture containing a compatibilizer, PET, and at least one other synthetic or natural polymer plastic (e.g., a non-PET plastic) bonded to a single physical phase. As used herein, the term “compatibilizer” means an agent that can bind together at least two polymers that would otherwise not mix in a physical mixture (i.e., a blend).

[0050]

[0067] In one embodiment or in combination with any embodiment described herein, MPW contains 20% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, or 0.1% by weight or less, on a dry plastic basis. In one embodiment or in combination with any embodiment described herein, MPW contains 0.01 to 20% by weight, 0.05 to 10% by weight, 0.1 to 5% by weight, or 1 to 2% by weight, on a dry plastic basis.

[0051]

[0068] In one embodiment or in combination with any embodiment described herein, MPW contains a multi-component plastic in dry plastic basis of 40% by weight or less, 20% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less. In one embodiment or in combination with any embodiment described herein, MPW contains a multi-component plastic in dry plastic basis of 0.1 to 40% by weight, 1 to 20% by weight, or 2 to 10% by weight. In one embodiment or in combination with any embodiment described herein, MPW contains a multi-layer plastic in dry plastic basis of 40% by weight or less, 20% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less. In one embodiment or in combination with any embodiment described herein, MPW contains a multi-layer plastic in dry plastic basis of 0.1 to 40% by weight, 1 to 20% by weight, or 2 to 10% by weight.

[0052]

[0069] In one embodiment or in combination with any embodiment described herein, the MPW feedstock to the chemical recycling facility 10 in flow 100 contains, on a dry basis, 20% by weight or less, 15% by weight or less, 12% by weight or less, 10% by weight or less, 8% by weight or less, 6% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight of biological waste material, with the total weight of the MPW feedstock being 100% by weight. The MPW feedstock contains, on a dry basis, 0.01 to 20% by weight, 0.1 to 10% by weight, 0.2 to 5% by weight, or 0.5 to 1% by weight of biological waste material, with the total weight of the MPW feedstock being 100% by weight. As used herein, the term “biological waste material” means material of biological origin or material of organic origin. Exemplary biological waste materials include, but are not limited to, cotton, wood, sawdust, food waste, animals and animal parts, plants and plant parts, and manure.

[0053]

[0070] In one embodiment or in combination with any embodiment described herein, the MPW raw material includes processed cellulose products in amounts of 20% by weight or less, 15% by weight or less, 12% by weight or less, 10% by weight or less, 8% by weight or less, 6% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less, based on a dry weight basis with respect to 100% of the total weight of the MPW raw material. The MPW raw material includes processed cellulose products in amounts of 0.01 to 20% by weight, 0.1 to 10% by weight, 0.2 to 5% by weight, or 0.5 to 1% by weight, based on a dry weight basis with respect to 100% of the total weight of the MPW raw material. As used herein, the term “processed cellulose products” means non-natural (i.e., artificial or mechanically produced) articles containing cellulosic fibers, and their waste. Exemplary processed cellulose products include, but are not limited to, paper and corrugated cardboard.

[0054]

[0071] In one embodiment or in combination with any embodiment described herein, the waste plastics (e.g., MPW) supplied to the chemical recycling facility may contain, on a basis of the total weight of the plastics in the waste plastic supply supplied to the chemical recycling facility, at least 0.001% by weight, at least 0.01% by weight, at least 0.05% by weight, at least 0.1% by weight, or at least 0.25% by weight, and / or 10% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, 0.75% by weight or less, or 0.5% by weight or less of polyvinyl chloride (PVC).

[0055]

[0072] Furthermore, or alternatively, the waste plastics (e.g., MPW) supplied to the chemical recycling facility may contain at least 0.1% by weight, at least 1% by weight, at least 2% by weight, at least 4% by weight, or at least 6% by weight, and / or 25% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 2.5% by weight of non-plastic solids. The non-plastic solids may include inert fillers (e.g., calcium carbonate, hydrated aluminum silicate, alumina trihydrate, calcium sulfate), rocks, glass, and / or additives (e.g., thixotropes, pigments and colorants, flame retardants, inhibitors, UV inhibitors and stabilizers, conductive metals or carbon, release agents such as zinc stearate, waxes, silicones, etc.).

[0056]

[0073] In one embodiment or in combination with any embodiment described herein, the MPW may contain at least 0.01% by weight, at least 0.1% by weight, at least 0.5% by weight, or at least 1% by weight, and / or 25% by weight or less, 20% by weight or less, 25% by weight or less, 10% by weight or less, 5% by weight or less, or 2.5% by weight or less of liquid, based on the total weight of the MPW flow or composition. The amount of liquid in the MPW may be in the range of 0.01 to 25% by weight, 0.5 to 10% by weight, or 1 to 5% by weight, based on the total weight of the MPW flow 100.

[0057]

[0074] In one embodiment or in combination with any embodiment described herein, MPW may contain at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, or at least 55% by weight, and / or 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, or 35% by weight of liquid, based on the total weight of the waste plastic. The liquid in the waste plastic may be in the range of 35-65% by weight, 40-60% by weight, or 45-55% by weight, based on the total weight of the waste plastic.

[0058]

[0075] In one embodiment or in combination with any embodiment described herein, the amount of textile (including textile fibers) in the MPW flow 100 in the line may be, on a weight basis of MPW, at least 0.1% by weight, or at least 0.5% by weight, or at least 1% by weight, or at least 2% by weight, or at least 5% by weight, or at least 8% by weight, or at least 10% by weight, or at least 15% by weight, or at least 20% by weight of material obtained from textile or textile fibers. The amount of textile (including textile fibers) contained in the MPW of flow 100 may be in the range of 50% by weight or less, 40% by weight or less, 30% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 8% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, 0.1% by weight or less, 0.05% by weight or less, 0.01% by weight or less, or 0.001% by weight or less. The amount of textile in MPW Flow 100 may be in the range of 0.1 to 50% by weight, 5 to 40% by weight, or 10 to 30% by weight, based on the total weight of MPW Flow 100.

[0059]

[0076] The MPW introduced into the chemical recycling facility 10 may include recycled textiles. Textiles may include natural and / or synthetic fibers, rovings, yarns, nonwovens, fabrics, and products made from or containing any of the aforementioned items. Textiles can be woven, knitted, knotted, sewn, or fringed, and may include compressed fibers, such as felt, embroidery, lace, crochet, braids, or nonwovens and materials. Textiles may include fabrics, and fibers separated from textiles, or other products containing fibers, scraps or off-spec fibers or yarns or fabrics, or other sources of unbundled fabrics and yarns. Textiles may also include raw fabrics made from staple fibers, continuous fibers, yarns, fiber bundles, twisted yarns, and / or spun yarns, finished fabrics produced by wet processing of raw fabrics, garments made from finished fabrics or other fabrics. Textiles include garments, interior furniture, and industrial textiles. Textiles may include post-industrial (pre-consumer) textiles, post-consumer textiles, or both.

[0060]

[0077] In one embodiment or in combination with any embodiment described herein, textiles may include clothing that can be generally defined as being worn by or made for the human body. Examples of such textiles include sports coats, suits, trousers, and casual or work pants, shirts, socks, sportswear, dresses, underwear, outerwear (such as rain jackets, winter jackets and coats), sweaters, protective clothing, uniforms, and accessories (such as scarves, hats, and gloves). Examples of textiles for interior furniture include furniture upholstery and slipcovers, carpets and rugs, curtains, bedding (such as sheets, pillowcases, duvets, comforters, and mattress covers), linens, tablecloths, towels, hand towels, and blankets. Examples of industrial textiles include seats, floor mats, trunk liners, and ceiling materials for means of transport (cars, airplanes, trains, buses); outdoor furniture and cushions, tents, backpacks, suitcases, ropes, conveyor belts, rolled felt, polishing cloths, rags, soil erosion control cloths and geotextiles; agricultural mats and screens; personal protective equipment; bulletproof vests; medical bandages; sutures; and tapes.

[0061]

[0078] Nonwoven fabrics classified as textiles do not include wet-laid nonwoven fabrics or articles manufactured therefrom. While various articles with the same function can be manufactured by dry or wet processes, articles manufactured from dry-laid nonwoven fabrics are classified as textiles. Suitable articles formed from the dry-laid nonwoven fabrics described herein include those for personal, consumer, industrial, food service, medical, and other end uses. Specific examples include, but are not limited to, baby wipes, flushable baby wipes, disposable diapers, training pants, feminine hygiene products (such as sanitary napkins and tampons), adult incontinence pads, underwear, or briefs, and pet training pads. Other examples include a variety of dry or wet wiping fibers for consumer use (personal care or household) and industrial use (such as food service, healthcare, or professional applications). Nonwoven fabrics can be used as stuffing for pillows, mattresses, and upholstery, as well as for quilts and comforters. In the medical and industrial fields, the nonwoven fabrics of the present invention can be used in consumer, medical, and industrial face masks, protective clothing, hats, and shoe covers, disposable sheets, surgical gowns, sterile cloths, bandages, and bandaging materials.

[0062]

[0079] Furthermore, the nonwoven fabrics described herein can be used in environmental fabrics, such as geotextiles and waterproof fabrics, oil and chemical absorbent pads, and building materials, such as soundproofing or heat insulating materials, tents, timber and soil covers and sheets. Nonwoven fabrics may also be used in other consumer end uses, such as carpet backings, packaging for consumer, industrial and agricultural goods, heat insulating or soundproofing materials, and various types of clothing.

[0063]

[0080] The dry nonwoven fabrics described herein may be used in a variety of filtration applications, including in means of transport (e.g., automobiles or airplanes), commercial, residential, industrial, or other special applications. Examples include filter elements for consumer or industrial air or liquid filters (gasoline, oil, water, etc.), nanofiber webs used in microfiltration, and end uses such as tea bags, coffee filters, and dryer sheets. Furthermore, the nonwoven webs described herein may be used to form various automotive parts (including, but not limited to, brake pads, trunk liners, carpet trim, and underpads).

[0064]

[0081] Textiles may include one or more types of natural fibers and / or one or more types of synthetic fibers. Examples of textile fiber combinations include all natural fibers, all synthetic fibers, two or more types of natural fibers, two or more types of synthetic fibers, one type of natural fiber and one type of synthetic fiber, one type of natural fiber and two or more types of synthetic fibers, two or more types of natural fibers and one type of synthetic fiber, and two or more types of natural fibers and two or more types of synthetic fibers.

[0065]

[0082] Natural fibers include those of plant or animal origin. Examples of natural fibers include cellulose, hemicellulose, and lignin. Examples of plant-derived natural fibers include hardwood pulp, softwood pulp, and wood flour, as well as other plant fibers such as wheat straw, rice straw, abaca, coconut fiber, cotton, flax, hemp, jute, bagasse, kapok, papyrus, ramie, rattan, vine, kenaf, abaca, heneken, sisal, soybean, grain straw, bamboo, reed, esparto grass, bagasse, sabay grass, milkweed floss, pineapple leaf fiber, switchgrass, and lignin-containing plants. Examples of animal-derived fibers include wool, silk, mohair, cashmere, goat hair, horsehair, bird fibers, camel hair, angora hair, and alpaca hair.

[0066]

[0083] Synthetic fibers are fibers synthesized or induced by chemical reactions, or regenerated fibers, and include, but are not limited to, rayon, viscose, mercerized fibers, or other types of regenerated cellulose (conversion of natural cellulose to soluble cellulose derivatives and subsequent regeneration), for example lyocell (also known as Tencel®), acetates such as cupro, modal, and polyvinyl acetate, polyamides including nylon, polyesters such as PET, olefin polymers such as polypropylene and polyethylene, polycarbonates, polysulfates, polysulfones, polyethers such as polyether urea known as spandex or elastane, polyacrylates, acrylonitrile copolymers, polyvinyl chloride (PVC), polylactic acid, polyglycolic acid, sulfopolyester fibers, and combinations thereof.

[0067]

[0084] Before entering the chemical recycling facility, the textiles may be reduced in size by shredding, cutting, crushing, kneading, grinding, or cutting to create reduced-size textiles. The textiles may also be densified (e.g., pelletized) before entering the chemical recycling facility. Examples of densification include extrusion (e.g., pelletization), molding (e.g., compaction), and agglomeration (e.g., by externally applied heat, heat generated by friction, or by the addition of one or more adhesives (which may be the spent polymer itself)). Alternatively or in addition, the textiles may be subjected to one or more of the processes described herein in any form before being processed in the remaining equipment of the chemical recycling facility 10 shown in Figures 1a and 1b.

[0068]

[0085] In one embodiment or in combination with any embodiment described herein, the combination of polyethylene terephthalate (PET) and one or more polyolefins (PO) constitutes at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of the waste plastic (e.g., MPW) supplied to the chemical recycling facility of flow 100 in Figures 1a and 1b. Polyvinyl chloride (PVC) accounts for at least 0.001% by weight, at least 0.01% by weight, at least 0.05% by weight, at least 0.1% by weight, at least 0.25% by weight, or at least 0.5% by weight, and / or 10% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, 0.75% by weight or less, or 0.5% by weight or less, based on the total weight of plastics in the waste plastics introduced into the chemical recycling facility 10.

[0069]

[0086] In one embodiment or in combination with any embodiment described herein, the waste plastic may contain at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of PET in the total weight of plastics in the waste plastic introduced into the chemical recycling facility 10.

[0070]

[0087] In one embodiment or in combination with any embodiment described herein, the waste plastic may contain PO in amounts of at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, and / or 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, and 35% by weight or less, or PO may be present in amounts ranging from 5 to 75% by weight, 10 to 60% by weight, or 20 to 35% by weight, based on the total weight of plastics in the waste plastic introduced into the chemical recycling facility 10.

[0071]

[0088] Waste plastics (e.g., MPW) introduced into chemical recycling facilities may be supplied from a variety of sources, including municipal recycling facilities (MRFs) or recycling facilities or other mechanical or chemical sorting or separation facilities, manufacturers, factories, commercial production facilities or retailers or dealers or wholesalers that hold post-industrial and pre-consumer recycled products, directly from households / businesses (unprocessed recyclables), landfills, collection centers, convenience stores, or from those stored at docks, ships, or warehouses. In one embodiment or in combination with any embodiment described herein, the source of waste plastics (e.g., MPW) does not include deposit refund facilities where consumers can deposit certain recyclable items (e.g., plastic containers, bottles) and receive a monetary refund from the State. In one embodiment or in combination with any embodiment described herein, the source of waste plastics (e.g., MPW) includes deposit refund facilities where consumers can deposit certain recyclable items (e.g., plastic containers, bottles) and receive a monetary refund from the State. Such return facilities are commonly found, for example, in grocery stores.

[0072]

[0089] In one embodiment or in combination with any embodiment described herein, waste plastics may be provided as waste streams from other processing facilities, such as municipal recycling facilities (MRFs) or recycling facilities, or as plastic-containing mixtures that include waste plastics separated by consumers and left to be collected at sidewalk curbs or central convenience stations. In one or more of these embodiments, the waste plastic includes one or more MRF products or by-products, recycling by-products, separated plastic-containing mixtures, and / or PET-containing waste plastics from plastic product manufacturing equipment, which may contain, on a dry plastic basis, at least 10% by weight, at least 20% by weight, at least 30% by weight, at least 40% by weight, at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, or at least 90% by weight, and / or 99.9% by weight or less, 99% by weight or less, 98% by weight or less, 97% by weight or less, 96% by weight or less, or 95% by weight or less of PET, and may be in the range of 10-99.9% by weight, 20-99% by weight, 30-95% by weight, or 40-90% by weight of PET.

[0073]

[0090] In one or more of these embodiments, the waste plastic may include a predetermined amount of PET-containing recycled by-products or plastic-containing mixtures containing at least 1% by weight, at least 10% by weight, at least 30% by weight, at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, or at least 90% by weight, and / or 99.9% by weight or less, 99% by weight or less, or 90% by weight or less of PET, and may be in the range of 1 to 99.9% by weight, 1 to 99% by weight, or 10 to 90% by weight of PET. The recycling facility may include processes that produce high-purity PET (at least 99% by weight or at least 99.9% by weight) recycled by-products, but which are in a form undesirable for mechanical recycling facilities. As used herein, the term “recycled by-products” means any material separated or recovered by a recycling facility that is not recovered as a clear rPET product, including colored rPET. The recycled by-products described above and below are generally considered waste and may be sent to landfills.

[0074]

[0091] In one or more of these embodiments, the waste plastic includes a predetermined amount of recycled wet fine powder containing at least 20% by weight, at least 40% by weight, at least 60% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight, and / or 99.9% by weight or less of PET, based on dry plastic. In one or more of these embodiments, the waste plastic includes a predetermined amount of colored plastic-containing mixture containing at least 1% by weight, at least 10% by weight, at least 20% by weight, at least 40% by weight, at least 60% by weight, at least 80% by weight, or at least 90% by weight, and / or 99.9% by weight or less of PET, or 99% by weight or less, based on dry plastic. In one or more of these embodiments, the waste plastic includes metal and a predetermined amount of eddy current waste flow containing at least 0.1% by weight, at least 1% by weight, at least 10% by weight, at least 20% by weight, at least 40% by weight, at least 60% by weight, or at least 80% by weight, and / or 99.9% by weight or less, 99% by weight or less, or 98% by weight or less of PET, based on dry plastic. In one or more of these embodiments, the waste plastic may also include a predetermined amount of recycler fragment rejects containing at least 0.1% by weight, at least 1% by weight, at least 10% by weight, at least 20% by weight, at least 40% by weight, at least 60% by weight, or at least 80% by weight, and / or 99.9% by weight or less, 99% by weight, or 98% by weight or less of PET, which may be in the range of 0.1 to 99.9% by weight, 1 to 99% by weight, or 10 to 98% by weight of PET. In one or more of these embodiments, the waste plastic contains a predetermined amount of dry fine powder containing at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, at least 99% by weight, and at least 99.9% by weight of PET, based on dry plastic.

[0075]

[0092] The chemical recycling facility 10 may include infrastructure for receiving waste plastics (e.g., MPW) as described herein, and may facilitate the delivery of waste plastics by any suitable type of vehicle, including, for example, trains, trucks, and / or ships. Such infrastructure may include facilities for assisting in the unloading of waste plastics from vehicles, as well as storage facilities and one or more transport systems for transporting waste plastics from the unloading area to the downstream processing area. Such transport systems may include, for example, pneumatic conveyors, belt conveyors, bucket conveyors, vibratory conveyors, screw conveyors, cart-on-track conveyors, tow conveyors, trolley conveyors, front-end loaders, trucks, chain conveyors, and the like.

[0076]

[0093] The waste (e.g., MPW) introduced into the chemical recycling facility 10 includes whole articles, particles (e.g., crushed, pelletized, fibrous plastic particles), bundled packages (e.g., articles compressed and banded together), unbundled articles (i.e., not in packages or boxes), containers (e.g., boxes, bags, trailers, railcars, loader buckets), piles (e.g., on concrete slabs of buildings), solid / liquid slurries (e.g., plastic pump-transport slurries in water), and / or loose materials transported physically (e.g., particles on a conveyor belt) or aerally (e.g., particles mixed with air and / or inert gas in a transport pipe).

[0077]

[0094] As used herein, the term “waste plastic particles” means waste plastic with a D90 of less than 1 inch. In one embodiment or in combination with any embodiment described herein, waste plastic particles may be MPW particles. Waste plastic or MPW particles may include, for example, shredded or fragmented pulverized plastic particles or plastic pellets. If a whole or nearly whole article is introduced into the chemical recycling facility 10 (or pretreatment facility 20), one or more pulverization or pelletizing processes may be used thereto to form waste plastic particles (e.g., MPW particles). Alternatively or in addition, at least a portion of the waste plastic introduced into the chemical recycling facility 10 (or pretreatment facility 20) may already be in the form of particles.

[0078]

[0095] Next, the general configuration and operation of each piece of equipment that may be present in the chemical recycling facility shown in Figures 1a and 1b will be described in more detail below, starting with the pretreatment equipment. If necessary, although not shown in Figures 1a and 1b, at least one of the flows from the chemical recycling facility may be sent to an industrial landfill or other similar type of treatment or disposal facility.

[0079] Pre-treatment

[0096] As shown in Figures 1a and 1b, untreated and / or partially treated waste plastics, such as mixed plastic waste (MPW), may first be introduced into the pretreatment facility 20 via flow 100. In the pretreatment facility 20, the flow may be subjected to one or more treatment steps to prepare it for chemical regeneration. As used herein, the term “pretreatment” means preparing the waste plastics for chemical regeneration using one or more of the following steps: (i) grinding, (ii) particleization, (iii) washing, (iv) drying, and (v) separation. As used herein, the term “pretreatment facility” means the facility including all the equipment, lines, and controls necessary for pretreatment of waste plastics. The pretreatment facilities described herein may employ any suitable method for preparing waste plastics for chemical regeneration using one or more of these steps, which are described in more detail below.

[0080] Grinding and particleization

[0097] In one embodiment or in combination with any embodiment described herein, waste plastic (e.g., MPW) may be provided in the form of unsorted or sorted plastic packages or other large aggregates. The packages or aggregates of plastic are first processed and thereafter separated. The plastic packages are sent to an unpacking machine which includes one or more rotating shafts equipped with teeth or blades configured to separate the packages and, optionally, shred the plastic containing the packages. In one or more other embodiments, the packages or aggregates of plastic are sent to a shredder which is cut into smaller pieces of plastic. The unpacked and / or shredded plastic is subjected to a sorting process to remove heavy non-plastic materials such as glass, metal, or stone. This sorting can be done by hand or by machine. The sorting machine may rely on optical sensors, magnets, eddy currents, pneumatic lifts or conveyors that separate based on drag coefficients, or sieves that identify and remove heavy materials.

[0081]

[0098] In one embodiment or in combination with any embodiment described herein, the waste plastic material includes plastic solids having a D90 of 1 inch or more, 0.75 inches or more, or 0.5 inches or more, such as used containers. Alternatively or in addition, the waste plastic material may include multiple plastic solids having dimensions greater than 1 inch at the same time, but the solids may be compressed, pressurized, or otherwise aggregated into larger units such as packaging. In such embodiments where at least some or all of the plastic solids have at least one dimension greater than 1 inch, greater than 0.75 inches, or greater than 0.5 inches, the supply material may be subjected to mechanical reduction operations such as crushing / graining, shredding, cutting, pulverizing, or other grinding processes to provide MPW particles with smaller dimensions. Such mechanical reduction operations may include reduction processes other than crushing, compressing, or forming the plastic into packaging.

[0082]

[0099] In one or more other embodiments, the waste plastic may have already undergone some initial separation and / or reduction process. In particular, the waste plastic may be in the form of particles or flakes and may be supplied in some container such as a bag or box. Depending on the composition of these plastic solids and the type of pretreatment they have received, the plastic supply material may bypass unpacking machines, cutting machines, and / or weight removal processes and proceed directly to a granulator for further reduction in size.

[0083]

[0100] In one embodiment or in combination with any embodiment described herein, the unpacked or disassembled plastic solids are sent to a crushing or granulating apparatus, where the plastic solids are crushed, shredded, or otherwise reduced in size. The plastic material can be reduced to particles having a D90 particle diameter of less than 1 inch, less than 3 / 4 inch, or less than 1 / 2 inch. In one or more other embodiments, the D90 particle diameter of the plastic material exiting the granulating apparatus is 1 / 16 inch to 1 inch, 1 / 8 inch to 3 / 4 inch, 1 / 4 inch to 5 / 8 inch, or 3 / 8 inch to 1 / 2 inch.

[0084] Washing and drying

[0101] In one embodiment or in combination with any embodiment described herein, untreated or partially treated waste plastics supplied to a chemical recycling facility may contain various organic contaminants or residues related to the waste plastics' previous use. For example, waste plastics may contain food and beverage contaminants, particularly if the plastic material was used for packaging food and beverages. Consequently, waste plastics may contain microbial contaminants and / or compounds produced by microorganisms. Exemplary microorganisms that may be present on the surface of the plastic solids constituting waste plastics include Escherichia coli, Salmonella, C. difficile, Staphylococcus aureus, L. monocytogenes, S. epidermidis, Pseudomonas aeruginosa, and P. fluorosens.

[0085]

[0102] Various microorganisms can produce compounds that cause malodors. Exemplary malodor-causing compounds include hydrogen sulfide, dimethyl sulfide, methanethiol, putrescine, cadaverine, trimethylamine, ammonia, acetaldehyde, acetic acid, propanoic acid, and / or butyric acid. Thus, it is natural that waste plastics can present the troublesome concern of odor. Therefore, waste plastics may be stored in a sealed space, such as a shipping container, a sealed rail car, or a sealed trailer, until further processing is carried out. In certain embodiments, untreated or partially treated waste plastics may be stored in a sealed space for up to one week, up to five days, up to three days, up to two days, or up to one day once they arrive at the place where the waste plastics are processed (e.g., crushing, washing, and sorting).

[0086]

[0103] In one embodiment or in combination with any embodiment described herein, the pretreatment equipment 20 may include an apparatus or process for treating waste plastic with a chemical composition having antimicrobial properties to form particulate plastic solids treated thereby. In some embodiments, this process may include treating waste plastic with sodium hydroxide, a high pH salt solution (e.g., potassium carbonate), or another antimicrobial composition.

[0087]

[0104] Furthermore, in one embodiment or in combination with any embodiment described herein, waste plastics (e.g., MPW) may be washed to remove inorganic, non-plastic solids such as dirt, glass, and fillers, and / or biological components such as bacteria and / or food. The resulting washed waste plastics may be dried to a moisture content of 5% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, or 0.25% by weight or less, based on the total weight of the waste plastics. Drying may be carried out by any suitable method, including the addition of heat and / or airflow, mechanical drying (e.g., centrifugation), or evaporation of liquid over a predetermined period of time.

[0088] separation

[0105] In one embodiment or in combination with any embodiment described herein, the pretreatment equipment 20 or process of the chemical recycling process or equipment 10 may include at least one separation step or compartment. The separation step or compartment may be configured to separate the waste plastic stream into two or more streams rich in a particular type of plastic. Such separation is particularly effective when the waste plastic supplied to the pretreatment equipment 20 is MPW.

[0089]

[0106] In one embodiment or in combination with any embodiment described herein, the separation section 22 (see Figure 2) of the pretreatment equipment 20 can separate waste plastic (e.g., MPW) into a PET enriched stream 112 and a PET depleted stream 114, as shown in Figure 2. As used herein, the term "enriched" means that the concentration (on an undiluted dry weight basis) of a particular component is higher than the concentration of that component in the reference material or stream. As used herein, the term "depleted" means that the concentration (on an undiluted dry weight basis) of a particular component is lower than the concentration of that component in the reference material or stream. Unless otherwise specified herein, all weight percents are expressed on an undiluted dry weight basis.

[0090]

[0107] When the enriching or depleting component is a solid, the concentration is based on the weight of the undiluted dry solid; when the enriching or depleting component is a liquid, the concentration is based on the weight of the undiluted dry liquid; and when the enriching or depleting component is a gas, the concentration is based on the weight of the undiluted dry gas. Furthermore, enrichment and depletion can be expressed in terms of mass equilibrium rather than in terms of concentration. Thus, an enriching flow of a particular component may have a mass of the component greater than the mass of the component in the reference flow (e.g., the feed flow or other product flow), while a depleting flow of a particular component may have a mass of the component less than the mass of the component in the reference flow (e.g., the feed flow or other product flow).

[0091]

[0108] Referring again to Figure 2, the PET-enriched stream 112 of waste plastic drawn from the pretreatment facility 20 (or separation section 22) may have a higher PET concentration or mass than the PET concentration or mass in the waste plastic supply stream 100 introduced into the pretreatment facility 20 (or separation section 22). Similarly, the PET-depleted stream 114 drawn from the pretreatment facility 20 (or separation section 22) may have a lower PET concentration or mass than the PET concentration or mass in the waste plastic introduced into the pretreatment facility 20 (or separation section 22), with the PET being depleted. The PET-depleted stream 114 may also be enriched with PO and may have a higher PO concentration or mass than the PO concentration or mass in the waste plastic (e.g., MPW) stream introduced into the pretreatment facility 20 (or separation section 22).

[0092]

[0109] In one embodiment or in combination with any embodiment described herein, when the MPW flow 100 is supplied to the pretreatment equipment 20 (or separation section 22), the PET enriched flow may be enriched in terms of the concentration or mass of PET relative to the concentration or mass of PET in the MPW flow, the PET depleted flow, or both, on a dry weight basis of the undiluted solid. For example, if the PET enriched flow is diluted with a liquid or other solid after separation, the enrichment is based on the concentration in the undiluted PET enriched flow and is based on the dry weight. In one embodiment or in combination with any embodiment described herein, the PET enriched flow 112 has a % PET enrichment rate for the MPW feed flow (PET enrichment rate (%) relative to the feed), the PET impoverished product flow 114 (PET enrichment rate (%) relative to the product), or both, determined by the following formula, which is at least 10%, at least 20%, at least 40%, at least 50%, at least 60%, at least 80%, at least 100%, at least 125%, at least 150%, at least 175%, at least 200%, at least 225%, at least 250%, at least 300%, at least 350%, at least 400%, at least 500%, at least 600%, at least 700%, at least 800%, at least 900%, or at least 1000%.

[0093]

number

[0094] In the formula, PETe is the concentration of PET in the PET enrichment product stream 112 on an undiluted dry weight basis. PETm is the concentration of PET in MPW feed stream 100 on a dry weight basis, and PETd is the concentration of PET in the PET-poorened product stream 114 on a dry weight basis.

[0095]

[0110] In one embodiment or in combination with any embodiment described herein, when a flow containing MPW 100 is supplied to the pretreatment equipment 20 (or separation section 22), the PET enriched flow is enriched with halogens such as fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds such as PVC, with respect to the concentration or mass of halogens in the MPW supply flow 100, the PET impoverished product flow 114, or both. In one embodiment or in combination with any embodiment described herein, the PET enriched flow 112 has a % PVC enrichment rate for the MPW feed flow 100 (PVC enrichment rate (%) relative to the feed), the PET impoverished product flow (PVC enrichment rate (%) relative to the product), or both, determined by the following formula, which is at least 1%, at least 3%, at least 5%, at least 7%, at least 10%, at least 15%, at least 20%, at least 40%, at least 50%, at least 60%, at least 80%, at least 100%, at least 125%, at least 150%, at least 175%, at least 200%, at least 225%, at least 250%, at least 300%, at least 350%, at least 400%, or at least 500%.

[0096]

number

[0097] In the formula, PVCe represents the concentration of PVC in the PET enrichment product stream 112 on an undiluted dry weight basis. PVCm is the concentration of PVC in MPW feed stream 100 on an undiluted dry weight basis, and PVCd is the concentration of PVC in PET-poorened product stream 114 on an undiluted dry weight basis.

[0098]

[0111] In one embodiment or in combination with any embodiment described herein, when the MPW stream 100 is supplied to the pretreatment equipment 20 (or separation section 22), the PET impoverished stream 114 is enriched with polyolefins on an undiluted solid-dry basis with respect to the concentration or mass of polyolefins in the MPW supply stream 100, the PET enriched product stream 112, or both. In one embodiment or in combination with any embodiment described herein, the PET impoverished flow 114 has a % polyolefin enrichment rate for the MPW feed flow 100 (PO enrichment rate (%) relative to the feed) or the PET enriched product flow 112 (PO enrichment rate (%) relative to the product), or both, determined by the following formula, which is at least 10%, at least 20%, at least 40%, at least 50%, at least 60%, at least 80%, at least 100%, at least 125%, at least 150%, at least 175%, at least 200%, at least 225%, at least 250%, at least 300%, at least 350%, at least 400%, at least 500%, at least 600%, at least 700%, at least 800%, at least 900%, or at least 1000%.

[0099]

number

[0100] In the formula, POd is the concentration of polyolefin in PET-poorened product stream 114 on an undiluted dry weight basis. POm is the concentration of PO in MPW feed stream 100 on a dry weight basis, and POe is the concentration of PO in PET enrichment product stream 112 on a dry weight basis.

[0101]

[0112] In one embodiment, or in combination with any other embodiment, when MPW flow 100 is supplied to pretreatment equipment 20 (or separation section 22), the PET impoverished flow 114 is impoverished with respect to the concentration or mass of halogens in the MPW flow 100, the PET enriched flow 112, or both, with respect to halogens such as fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds such as PVC. In one embodiment or in combination with any embodiment described herein, the PET impoverished flow 114 has a % PVC impoverishment rate relative to the MPW feed flow 100 (PVC impoverishment rate (%) relative to the feed) or the PET enriched product flow 112 (PVC impoverishment rate (%) relative to the product), which is determined by the following formula: at least 1%, at least 3%, at least 5%, at least 7%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, or at least 90%.

[0102]

number

[0103] In the formula, PVCm is the concentration of PVC in MPW feed stream 100 on an undiluted dry weight basis. PVCd is the concentration of PVC in the PET poor product stream 114 on an undiluted dry weight basis, and PVCe is the PVC concentration in PET enrichment product stream 112 on an undiluted dry weight basis.

[0104]

[0113] The PET-poorened flow 114 is PET-poorened with respect to the concentration or mass of PET in the MPW flow 100, the PET-enriched flow 112, or both. In one embodiment or in combination with any embodiment described herein, the PET-poorened flow 114 has a % PET-poorening rate with respect to the MPW feed flow 100 (PET-poorening rate (%) relative to the feed) or the PET-enriched product flow 112 (PET-poorening rate (%) relative to the product) determined by the following formula, which is at least 1%, at least 3%, at least 5%, at least 7%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, or at least 90%.

[0105]

number

[0106] In the formula, PETm is the concentration of PET in MPW feed stream 100 on an undiluted dry weight basis. PETd is the PET concentration in the PET-poored product stream 114 on an undiluted dry weight basis, and PETe is the concentration of PET in PET enrichment product stream 112 on an undiluted dry weight basis.

[0107]

[0114] In any of the above embodiments, the enrichment or depletion rate is the average over a week, a three-day period, or a one-day period, and the measurement can be carried out in a manner that reasonably correlates the sample taken at the outlet of the treatment with respect to the MPW volume, which takes into account the MPW residence time during which the MPW sample flows from the inlet to the outlet. For example, if the average residence time of the MPW is 2 minutes, the outlet sample will be taken 2 minutes after the inlet sample, and the samples will correlate with each other.

[0108]

[0115] In one embodiment or in combination with any embodiment described herein, the PET enriched stream leaving the separation section 22 or the pretreatment equipment 20 may contain at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 97% by weight, at least 99% by weight, at least 99.5% by weight, or at least 99.9% by weight of PET in the PET enriched stream 112, based on the total weight of plastics. The PET enriched stream 112 may be PVC enriched, for example, on a basis of the total weight of plastics in the PET enriched stream, it may contain halogens including PVC in amounts of at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 5% by weight, and / or 10% by weight or less, 8% by weight or less, 6% by weight or less, 5% by weight or less, or 3% by weight or less, or on a basis of the total weight of plastics in the PET enriched stream, it may be in the range of 0.1 to 10% by weight, 0.5 to 8% by weight, or 1 to 5% by weight. The PET enriched stream may contain at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 99% by weight, or at least 99.5% by weight of the total amount of PET introduced into the pretreatment equipment 20 (or separation compartment 22).

[0109]

[0116] PET-enriched flow 112 is suitable for PO and / or heavier plastics, such as polytetrafluoroethylene (PTFE), polyamides (PA12, PA46, PA66), polyacrylamide (PARA), polyhydroxybutyrate (PHB), blends of polycarbonate and polybutylene tetraphthalate (PC / PBT), polyvinyl chloride (PVC), polyimide (PI), polycarbonate (PC), polyethersulfone (PESU), polyetheretherketone (PEEK), polyamideimide (PAI), polyethyleneimine (PEI), polysulfone (PSU), polyoxymethylene (POM), polyglycolide (polyglycolic acid, PGA), and polyphenylene. Sulfides (PPS), thermoplastic styrene elastomers (TPS), amorphous thermoplastic polyimides (TPI), liquid crystal polymers (LCP), glass fiber reinforced PET, chlorinated polyvinyl chloride (CPVC), polybutylene tephthalate (PBT), polyphthalamide (PPA), polyvinylidene chloride (PVDC), ethylene tetrafluoroethylene (ETFE), polyvinylidene fluoride (PVDF), fluorinated ethylene propylene (FEP), polymonochlorotrifluoroethylene (PCTFE), and perfluoroalkoxys (PFA) may be impoverished, and all of these may contain carbon, glass, and / or mineral fillers, and have a higher density than PET and PVC.

[0110]

[0117] In one embodiment or in combination with any embodiment described herein, the PET enriched flow 112 may contain PO at a rate of 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less, based on the total weight of plastics in the PET enriched flow 112. The PET enriched flow 112 may also contain 10% by weight or less, 8% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less, of the total amount of PO introduced into the pretreatment equipment 20 (or separation compartment 22). PET enriched flow 112 may contain 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, and 1% by weight or less of components other than PET, based on the total weight of PET enriched flow 112.

[0111]

[0118] Furthermore, or alternatively, the PET-enriched flow 112 may contain adhesives in amounts of 2% by weight or less, 1% by weight or less, 0.5% by weight or less, or 0.1% by weight or less on a dry basis. Typical adhesives include carpet adhesives, latex, styrene-butadiene rubber, etc. In addition, the PET-enriched flow 112 may contain plastic fillers and solid additives in amounts of 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, or 0.1% by weight or less on a dry basis. Exemplary fillers and additives include silicon dioxide, calcium carbonate, talc, silica, glass, glass beads, alumina, and other solid inert substances, which do not chemically react with plastics or other components in the processes described herein.

[0112]

[0119] In one embodiment or in combination with any embodiment described herein, the PET-purged (or PO-enriched) stream 114 exiting the separation compartment 22 or pretreatment equipment 20 may contain at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 97% by weight, at least 99% by weight, or at least 99.5% by weight of PO in the total weight of plastics in the PET-purged (or PO-enriched) stream 114. The PET-purged (or PO-enriched) stream may also be PVC-purged, and may contain, for example, 5% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, 0.1% by weight or less, 0.05% by weight or less, or 0.01% by weight or less of halogens containing chlorine in the PVC, based on the total weight of plastics in the PET-purged (or PO-enriched) stream. The PET-depleted or PO-enriched stream may contain at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 99% by weight, or at least 99.9% by weight of the total amount of PO introduced into the pretreatment equipment 20 or separation equipment 22.

[0113]

[0120] The PO-enriched stream 114 may also be impoverished with other plastics, including PET and / or PVC. In one embodiment or in combination with any embodiment described herein, the PET-impoverished (or PO-enriched) stream may contain 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight of PET, based on the total weight of plastics in the PET-impoverished or PO-enriched stream. The PO-enriched (or PET-impoverished) stream 114 may also contain 10% by weight or less, 8% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less of the total amount of PET introduced into the pretreatment equipment.

[0114]

[0121] In one embodiment or in combination with any embodiment described herein, the PET impoverished or PO enriched flow 114 may contain components other than PO in amounts of 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less, based on the total weight of the PET impoverished or PO enriched flow 114. The PET impoverished or PO enriched flow 114 contains adhesive in amounts of 4% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, or 0.1% by weight or less, based on the total weight of the flow.

[0115]

[0122] In one embodiment or in combination with any embodiment described herein, the PET-purging or PO-enriching flow 114 is measured using a Brookfield R / S viscometer equipped with a V80-40 blade spindle operating at a shear rate of 10 rad / s and a temperature of 350°C, and is at least 1 poise, at least 5 poise, at least 50 poise, at least 100 poise, at least 200 poise, at least 300 poise, at least 400 poise, at least 500 poise, at least 600 poise, at least 700 poise, at least 800 poise, at least 900 poise, at least 1,000 poise, It may have a melt viscosity of at least 1,500 poise, at least 2,000 poise, at least 2,500 poise, at least 3,000 poise, at least 3,500 poise, at least 4,000 poise, at least 4,500 poise, at least 5,000 poise, at least 5,500 poise, at least 6,000 poise, at least 6,500 poise, at least 7,000 poise, at least 7,500 poise, at least 8,000 poise, at least 8,500 poise, at least 9,000 poise, at least 9,500 poise, or at least 10,000 poise. Alternatively, or in addition to the above, the PET-purged or PO-enriched flow may have a melt viscosity of 25,000 poise or less, 24,000 poise or less, 23,000 poise or less, 22,000 poise or less, 21,000 poise or less, 20,000 poise or less, 19,000 poise or less, 18,000 poise or less, or 17,000 poise or less (measured at 10 rad / s and 350°C). Or, the flow may have a melt viscosity in the range of 1 to 25,000 poise, 500 to 22,000 poise, or 1,000 to 17,000 poise (measured at 10 rad / s and 350°C).

[0116]

[0123] Any suitable type of separation device, system, or equipment may be employed to separate waste plastics into two or more flows enriched with a specific type of plastic, such as PET enriched flow 112 and PO enriched flow 114. Examples of suitable types of separation include mechanical separation and density separation, which include sedimentation-flotation separation and / or centrifugal density separation. As used herein, the term “sedimentation-flotation separation” means a density separation process in which the separation of materials is caused primarily by flotation or sedimentation in a selected liquid medium. The term “centrifugal density separation” means a density separation process in which the separation of materials is caused primarily by centrifugal force. Generally, the term “density separation process” means a process that separates materials into at least high-density products and low-density products based at least in part on the density of each material, and includes both sedimentation-flotation separation and centrifugal density separation.

[0117]

[0124] When sedimentation-flotation separation is used, the liquid medium may include water. To increase the density of the liquid medium and adjust the target separation density in the sedimentation-flotation separation stage, for example, salts, sugars, and / or other additives may be added to the liquid medium. The liquid medium may include a concentrated salt aqueous solution. In one or more such embodiments, the salt is sodium chloride, but in one or more other embodiments, the salt is a non-halogenated salt, such as acetate, carbonate, citrate, nitrate, nitrite, phosphate, and / or sulfate. The liquid medium may include a concentrated salt solution containing sodium bromide, sodium dihydrogen phosphate, sodium hydroxide, sodium iodide, sodium nitrate, sodium thiosulfate, potassium acetate, potassium bromide, potassium carbonate, potassium hydroxide, potassium iodide, calcium chloride, cesium chloride, iron chloride, strontium chloride, zinc chloride, manganese sulfate, magnesium sulfate, zinc sulfate, and / or silver nitrate. In one embodiment or in combination with any embodiment described herein, the salt is a caustic component. The salt may contain sodium hydroxide, potassium hydroxide, and / or potassium carbonate. The concentrated salt solution may have a pH of 7 or higher, 8 or higher, 9 or higher, or 10 or higher.

[0118]

[0125] In one embodiment or in combination with any embodiment described herein, the liquid medium may contain sugars such as sucrose. The liquid medium may also contain carbon tetrachloride, chloroform, dichlorobenzene, dimethyl sulfate, and / or trichloroethylene. The specific components and concentrations of the liquid medium are selected according to the desired target separation density of the separation stage. The centrifugal density separation process may also utilize the above-mentioned liquid medium to improve the separation efficiency at the target separation density.

[0119]

[0126] In one embodiment or in combination with any embodiment described herein, a waste plastic separation method comprises at least two density separation stages. In a particular such embodiment, the method generally comprises introducing waste plastic particles into a first density separation stage and feeding the product from the first density separation stage into a second density separation stage. The density separation stages may be any system or unit operation that performs the density separation process, as defined herein. At least one of the density separation stages comprises a centrifugal separation stage or a sedimentation-flotation separation stage. Each of the first and second density separation stages comprises a centrifugal separation stage and / or a sedimentation-flotation separation stage.

[0120]

[0127] To generate a PET-enriched material flow, one of the density separation steps may include a low-density separation step, and the other may generally include a high-density separation step. As defined herein, the low-density separation step has a target separation density lower than that of the high-density separation step. The low-density separation step has a target separation density less than the density of PET, and the high-density separation step has a target separation density greater than the density of PET.

[0121]

[0128] As used herein, the term "target separation density" refers to the density at which a material subjected to a density separation process is preferentially separated into high-density products, and materials below that density are separated into low-density products. The target separation density specifies a density value, and it is intended that all plastics and other solid materials with a density higher than that value are separated into high-density products, and all plastics and other solid materials with a density lower than that value are separated into low-density products. However, the actual separation efficiency of materials in the density separation process may depend on various factors, such as residence time, the relative proximity of the density of a particular material to the target density separation value, and factors related to particle morphology, such as area / mass ratio, sphericity, and porosity.

[0122]

[0129] In one embodiment or in combination with any embodiment described herein, the low-density separation stage has a target separation density of less than 1.35, less than 1.34, less than 1.33, less than 1.32, less than 1.31, or less than 1.30 g / cc, and / or at least 1.25, at least 1.26, at least 1.27, at least 1.28, or at least 1.29 g / cc. The high-density separation stage has a target separation density at least 0.01 g / cc, at least 0.025 g / cc, at least 0.05 g / cc, at least 0.075 g / cc, at least 0.1 g / cc, at least 0.15 g / cc, or at least 0.2 g / cc higher than the target separation density of the low-density separation stage. The target separation density for the high-density separation stage is at least 1.31 g / cc, at least 1.32 g / cc, at least 1.33 g / cc, at least 1.34 g / cc, at least 1.35 g / cc, at least 1.36 g / cc, at least 1.37 g / cc, at least 1.38 g / cc, at least 1.39 g / cc, or at least 1.40 g / cc, and / or 1.45 g / cc or less, 1.44 g / cc or less, 1.43 g / cc or less, 1.42 g / cc or less, or 1.41 g / cc or less. The target separation density for the low-density separation stage is in the range of 1.25 to 1.35 g / cc, and the target separation density for the high-density separation stage is in the range of 1.35 to 1.45 g / cc.

[0123]

[0130] Referring again to Figures 1a and 1b, both the PET enriched stream 112 and the PO enriched stream 114 may be introduced into one or more downstream processing facilities within the chemical regeneration facility 10 (or may go through one or more downstream processing steps). In one embodiment or in combination with any embodiment described herein, at least a portion of the PET enriched stream 112 may be introduced into the solvolysis facility 30. On the other hand, at least a portion of the PO enriched stream 114 may be introduced directly or indirectly into one or more of the pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, energy recovery facility 80, or other facilities 90, such as solidification or separation facilities. Further details regarding the types of each process and facility, and the general integration of each of these processes or facilities with one or more others according to one or more embodiments of the Art, will be described in further detail below.

[0124] Solvolysis

[0131] In one embodiment or in combination with any embodiment described herein, at least a portion of the PET enriched stream 112 from the pretreatment equipment 20 may be introduced into the solvolysis equipment 30. As used herein, the terms “solvolysis” or “ester solvolysis” refer to a reaction in which an ester-containing feed is chemically decomposed in the presence of a solvent to produce a major carboxyl product and a major glycol product. A “solvolysis equipment” is a facility that includes all the equipment, lines, and control units necessary for solvolysis of waste plastics and derived raw materials.

[0125]

[0132] If the ester subjected to solvolysis contains PET, the solvolysis performed in the solvolysis equipment may be PET solvolysis. As used herein, the term "PET solvolysis" means a reaction in which a terephthalic acid polyester-containing feed is chemically decomposed in the presence of a solvent to produce a major terephthalyl product and a major glycol product. As used herein, the term "major terephthalyl" means the major or important terephthalyl product recovered from the solvolysis equipment. As used herein, the term "major glycol" means the major glycol product recovered from the solvolysis equipment. As used herein, the term "glycol" means a component containing two or more -OH functional groups per molecule. As used herein, the term "terephthalyl" means a molecule containing the following groups:

[0126] [ka]

[0127]

[0133] In one embodiment or in combination with any embodiment described herein, the main terephthalyl product comprises terephthalic acid or dimethyl terephthalate (or its oligomer), and the main glycol comprises glycols such as ethylene glycol and / or diethylene glycol. The main steps of the PET solvolysis apparatus 30 according to one or more embodiments of the present technology are schematically shown in Figure 3.

[0128]

[0134] In one embodiment or in combination with any embodiment described herein, the primary solvent used in solvolysis comprises a chemical compound having at least one -OH group. Suitable solvents include, but are not limited to, (i) water (in which case solvolysis may be called "hydrolysis"), (ii) alcohols (in which case solvolysis may be called "alcoholic decomposition"), e.g., methanol (in which case solvolysis may be called "methanolic decomposition") or ethanol (in which case solvolysis may be called "ethanolic decomposition"), (iii) glycols, e.g., ethylene glycol or diethylene glycol (in which case solvolysis may be called "glycolic decomposition"), or (iv) ammonia (in which case solvolysis may be called "ammoniaic decomposition").

[0129]

[0135] In one embodiment or in combination with any embodiment described herein, the solvolysis solvent may contain at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of the main solvent, based on the total weight of the solvent stream. In one embodiment or in combination with any embodiment described herein, the solvent may contain other solvents or components in an amount of 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less, based on the total weight of the solvent stream.

[0130]

[0136] In one embodiment or in combination with any embodiment described herein, the main solvent, i.e., the solvolytic solvent, may contain 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight of a nonpolar solvent, based on the total weight of the solvent flow or composition. The main solvent, i.e., the solvolytic solvent, may also contain 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less of a chlorinated solvent, based on the total weight of the solvent flow or composition.

[0131]

[0137] When the solvolysis equipment 30 uses glycols such as ethylene glycol as the main solvent, the equipment may be called a solvolysis equipment. In one embodiment or in combination with any embodiment described herein, the chemical regeneration facility in Figures 1a and 1b may include a glycol decomposition equipment. In a glycol decomposition equipment, PET can be chemically decomposed to produce ethylene glycol (EG) as the main glycol and dimethyl terephthalate (DMT) as the main terephthalyl. When PET contains waste plastic, the EG and DMT produced in the solvolysis equipment may both include regenerated ethylene glycol (regenerated EG) and regenerated dimethyl terephthalate (regenerated DMT) as regenerated components. When produced by glycol decomposition, EG and DMT may exist in a single product stream.

[0132]

[0138] When a solvolysis facility uses methanol as its primary solvent, it is sometimes called a methanol-based solvolysis facility. The chemical recycling facilities shown in Figures 1a and 1b may include methanol-based solvolysis facilities. In one example of a methanol-based solvolysis facility schematically shown in Figure 3, PET can be chemically decomposed to produce ethylene glycol (EG) as the primary glycol and dimethyl terephthalate (DMT) as the primary terephthalate. When the PET contains waste plastic, the EG and DMT produced in the solvolysis facility may both include recycled ethylene glycol (recycled EG) and recycled dimethyl terephthalate (recycled DMT) as recycled components.

[0133]

[0139] In one embodiment or in combination with any embodiment described herein, the glycol 154 (recycled glycol) stream of regenerated components withdrawn from the solvolysis equipment 30 may contain at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of the main glycol produced in the solvolysis equipment. Furthermore, this flow may also contain, based on the total weight of the flow, 99.9% by weight or less, 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, or 75% by weight or less of major glycols (such as EG), and / or at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 20% by weight or less, and / or 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, or 15% by weight or less of components other than major glycols, or these components may be present in amounts ranging from 0.5 to 45% by weight, 1 to 40% by weight, or 2 to 15% by weight. Recycled glycol may be present in flow 154 in amounts ranging from 45–99.9% by weight, 55–99.9% by weight, or 80–99.9% by weight, based on the total weight of flow 154.

[0134]

[0140] In one embodiment or in combination with any embodiment described herein, the stream 158 of the main terephthalyl (regenerated terephthalyl) of the regenerated component taken out of the solvolysis equipment may contain at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of the main terephthalyl (such as DMT) produced in the solvolysis equipment 30. This stream may contain 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, or 75% by weight or less of the main terephthalyl, or the main terephthalyl may be present in amounts of 45-99% by weight, 50-90% by weight, or 55-90% by weight, based on the total weight of the stream. In addition to or instead of this, the flow may contain, on a basis of the total weight of the flow, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 20% by weight, or at least 25% by weight, and / or 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, or 15% by weight or less of any component other than the main terephthalyl. Regenerated terephthalyl (or terephthalyl) may be present in flow 154 in amounts ranging from 45 to 99.9% by weight, 55 to 99.9% by weight, or 80 to 99.9% by weight, on a basis of the total weight of flow 154.

[0135]

[0141] In addition to providing a major glycol stream of the regenerated component and a major terephthalyl stream of the regenerated component, the solvolysis equipment may also provide one or more solvolysis byproduct streams (shown as stream 110 in Figures 1a and 1b) that may be drawn from one or more locations within the solvolysis equipment. As used herein, the terms “byproduct” or “solvolysis byproduct” mean any compound from the solvolysis equipment that is not the major carboxyl (terephthalyl) product of the solvolysis equipment, the major glycol product of the solvolysis equipment, or the major solvent supplied to the solvolysis equipment. The solvolysis byproduct stream may contain one or more solvolysis byproducts in an amount of at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight, based on the total weight of the stream.

[0136]

[0142] The solvolysis byproducts may include heavy organic solvolysis byproduct streams or light organic solvolysis byproduct streams. As used herein, "heavy organic solvolysis byproducts" means solvolysis byproducts having a boiling point higher than the boiling point of the main terephthalyl product of the solvolysis equipment, and "light organic solvolysis byproducts" means solvolysis byproducts having a boiling point lower than the boiling point of the main terephthalyl product of the solvolysis equipment.

[0137]

[0143] If the solvolysis equipment is a methanol-decomposition equipment, one or more methanol-decomposition byproducts may be removed from the equipment. As used herein, the term “methanol-decomposition byproducts” means compounds from the methanol-decomposition equipment other than DMT, EG, or methanol. The methanol-decomposition byproduct stream may contain, on a weight basis of the total weight of the stream, one or more solvolysis byproducts in amounts of at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight. In one embodiment or in combination with any embodiment described herein, the methanol-decomposition byproduct stream may contain heavy organic methanol-decomposition byproducts or light organic methanol-decomposition byproducts. As used herein, the term "heavy organic methanol decomposition by-product" refers to methanol decomposition by-products having a boiling point higher than DMT, and the term "light methanol decomposition by-product" refers to methanol decomposition by-products having a boiling point lower than DMT.

[0138]

[0144] In one embodiment or in combination with any embodiment described herein, the solvolysis apparatus may produce at least one heavy organic solvolysis byproduct stream. The heavy organic solvolysis byproduct stream may contain, on a basis of the total weight of organic matter in the stream, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of organic compounds having a boiling point higher than the boiling point of the main terephthalyl (such as DMT) produced from the solvolysis apparatus 30.

[0139]

[0145] Furthermore, or alternatively, the solvolysis apparatus may produce at least one light organic solvolysis byproduct stream. The light organic solvolysis byproduct stream may contain, on a basis of the total weight of organic matter in the stream, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of organic compounds having a boiling point lower than the boiling point of the main terephthalyl (such as DMT) produced from the solvolysis apparatus 30.

[0140]

[0146] Referring again to Figure 3, during operation, a feed stream 112 containing, for example, mixed plastic waste may be introduced into the solvolysis unit 30 together with the solvent stream 212 (separately or together via the mixing compartment 206). In one embodiment or in combination with any embodiment described herein, the feed stream 112 to the solvolysis unit 30 shall be, based on the total weight of the feed stream 112, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, and at least The composition may contain waste plastics in amounts of 90% by weight, or at least 95% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, or 10% by weight or less, or on a basis of the total weight of the supply flow 112, in amounts of 5-99% by weight, 10-95% by weight, or 15-90% by weight. Amounts of waste plastics within these ranges may also be present in the composition or various flows within the solvolysis equipment (e.g., reactor or mixing compartment 206).

[0141]

[0147] The waste plastics introduced into the solvolysis plant 30 may include mixed waste plastics, such as a mixture of polyethylene terephthalate (PET), polyolefin (PO), and polyvinyl chloride (PVC). For example, in one or more embodiments, the waste plastics introduced into the solvolysis plant 30 may be, on a dry basis, at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, and at least 85% by weight, relative to the total weight of the feed stream 112. The flow may contain PET in amounts of 1-99.9% by weight, at least 90% by weight, or at least 95% by weight, and / or 99.9% by weight or less, 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, or 25% by weight or less, or the flow may contain PET in amounts of 1-99.9% by weight, 2-99% by weight, or 5-95% by weight based on the total weight of flow 112.

[0142]

[0148] Alternatively, or in addition, the waste plastics introduced into the solubilization equipment may contain, on a dry basis, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, or at least 45% by weight, and / or 90% or less by weight, 80% or less by weight, 70% or less by weight, 65% or less by weight, 60% or less by weight, 55% or less by weight, 50% or less by weight, 45% or less by weight, 40% or less by weight, 35% or less by weight, 30% or less by weight, 25% or less by weight, 20% or less by weight, 15% or less by weight, or 10% or less of polyolefins, or the flow may contain polyolefins in amounts ranging from 5 to 90% by weight, 10 to 80% by weight, or 15 to 50% by weight, on a dry basis, relative to the total weight of the supply flow 112.

[0143]

[0149] In one or more embodiments, the waste plastic supplied to the solvolysis equipment may contain, on a dry basis, at least 0.001% by weight, at least 0.01% by weight, at least 0.05% by weight, at least 0.1% by weight, or at least 0.25% by weight, and / or 10% by weight or less, 8% by weight or less, 6% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, 0.75% by weight or less, or 0.5% by weight or less of halogens, based on the total weight of the flow 112, or in the range of 0.001 to 10% by weight, 0.1 to 8% by weight, or 0.25 to 3% by weight.

[0144]

[0150] Before being introduced into the solvolysis unit 30, the waste plastics may be sorted in the pretreatment unit 20, as shown in Figures 1a and 1b and already described, or they may be introduced directly into the solvolysis unit 30 without sorting. As previously stated, when sorted into PET-enriched waste plastic streams (such as stream 112 shown in Figures 1a and 1b) and PO-enriched waste plastic streams (such as stream 114 shown in Figures 1a and 1b), at least a portion of the PET-enriched stream 112 is introduced into the solvolysis unit 30, while at least a portion or all of the PO-enriched stream 114 may be introduced into one or more chemical treatment facilities, including (i) a partial oxidation (POX) unit 50, (ii) a pyrolysis unit 60, (iii) a cracking unit 70, (iv) an energy recovery unit 80, and (v) a liquefaction unit 40.

[0145]

[0151] As shown in Figure 3, the flow, which is mainly liquid, may first pass through any non-PET separation compartment 208, where at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of the total weight of the non-PET components is separated and removed. The non-PET components may have a lower boiling point than PET and may be removed as vapor from compartment 208. Alternatively or in addition, at least a portion of the non-PET components may have a density slightly higher or lower than PET, form a two-phase liquid flow, and then be separated by removing one or both of the non-PET phases. Finally, in some embodiments, the non-PET components may be separated as a solid from the liquid phase containing PET.

[0146]

[0152] In one embodiment or in combination with any embodiment described herein, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the non-PET components separated from the PET-containing stream include polyolefins such as polyethylene and / or polypropylene. As schematically shown by dashed lines in Figure 3, all or part of the non-PET separation compartment 208 may be upstream of the reaction compartment 210, or conversely, all or part of the non-PET separation compartment 208 may be downstream of the reaction compartment 210. Non-PET components may be separated from the PET-containing stream in the non-PET separation compartment 208 using separation techniques such as extraction, solid / liquid separation, decantation, cyclone or centrifugation, manual removal, magnetic removal, eddy current removal, chemical decomposition, vaporization and degassing, distillation, and combinations thereof.

[0147]

[0153] As shown in Figure 3, the PET-containing stream 138 exiting the non-PET separation compartment 208 may contain 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less of other components (or their oligomers and monomer decomposition products) and solvents based on the total weight of the PET-containing stream. The PET-containing stream 138 exiting the non-PET separation compartment 208 may also contain 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less of other types of plastics (such as polyolefins). The PET-containing stream 138 exiting the non-PET separation compartment 208 may contain 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 10% by weight or less, 5% by weight or less, or 2% by weight or less of the total amount of non-PET components introduced into the non-PET separation compartment 208.

[0148]

[0154] Non-PET components may be removed from the solvolysis (or methanol solvolysis) equipment 30 as a polyolefin-containing byproduct stream 140, as schematically shown in Figure 3. The polyolefin-containing byproduct stream (or decanter olefin byproduct stream) 140 may contain, on a basis of the total weight of the byproduct stream 140, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 92% by weight, at least 95% by weight, at least 97% by weight, at least 99% by weight, or at least 99.5% by weight of polyolefins.

[0149]

[0155] The polyolefins present in the polyolefin-containing byproduct stream may consist mainly of polyethylene, mainly of polypropylene, or a combination of polyethylene and polypropylene. The polyolefins in the polyolefin-containing byproduct stream may consist of at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 92% by weight, at least 94% by weight, at least 95% by weight, at least 97% by weight, at least 98% by weight, or at least 99% by weight of polyethylene, on a basis of the total weight of polyolefins in the polyolefin-containing byproduct stream 140. Alternatively, the polyolefins in the polyolefin-containing byproduct stream may consist of at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 92% by weight, at least 94% by weight, at least 95% by weight, at least 97% by weight, at least 98% by weight, or at least 99% by weight of polypropylene, on a basis of the total weight of polyolefins in the polyolefin-containing byproduct stream 140.

[0150]

[0156] The polyolefin-containing by-product stream contains PET in amounts of 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, 0.75% by weight or less, 0.50% by weight or less, 0.25% by weight or less, 0.10% by weight or less, or 0.05% by weight or less, based on the total weight of the polyolefin-containing by-product stream 140. Furthermore, the polyolefin-containing by-product stream contains non-polyolefin components in amounts of at least 0.01% by weight, at least 0.05% by weight, at least 0.10% by weight, at least 0.50% by weight, at least 1% by weight or at least 1.5% by weight, and / or 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 2% by weight or less, based on the total weight of the polyolefin-containing by-product stream 140.

[0151]

[0157] Overall, the polyolefin-containing byproduct stream 140 contains at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of organic compounds, based on the total weight of the polyolefin-containing byproduct stream 140. The polyolefin-containing byproduct stream 140 may also contain at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 5% by weight, at least 10% by weight, or at least 15% by weight, and / or 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less of inorganic components, based on the total weight of the polyolefin-containing byproduct stream 140.

[0152]

[0158] In one embodiment or in combination with any embodiment described herein, the polyolefin-containing byproduct stream is at least 1 poise, at least 10 poise, at least 25 poise, at least 50 poise, at least 75 poise, at least 90 poise, at least 100 poise, at least 125 poise, at least 150 poise, at least 200 poise, at least 250 poise, at least 300 poise, at least 350 poise, at least 400 poise, and at least 450 poise, at least 500 poise, at least 600 poise, at least 650 poise, at least 700 poise, at least 750 poise, at least 800 poise, at least 850 poise, at least 900 poise, or at least 950 poise, and / or 25,000 poise or less, 24,000 poise or less, 23,000 poise or less, 22,000 poise or less, 21,000 poise or less, 20,000 poise or less, 19,000 poise or less , 18,000 poise or less, 17,000 poise or less, 16,000 poise or less, 15,000 poise or less, 14,000 poise or less, 13,000 poise or less, 12,000 poise or less, 11,000 poise or less, 10,000 poise or less, 9,000 poise or less, 8,000 poise or less, 7,000 poise or less, 6,000 poise or less, 5,000 poise or less, 4,500 poise or less, 4,000 poise or less, 3,500 poise or less, 3,000 poise or less, 2 The viscosity may be 500 poise or less, 2,000 poise or less, 1,750 or less, 1,500 poise or less, 1,250 or less, 1,200 poise or less, 1,150 or less, 1,100 poise or less, 1,050 poise or less, 1,000 poise or less, 950 poise or less, 900 poise or less, 800 poise or less, and 750 poise or less (measured with a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / s and a temperature of 250°C). The polyolefin-containing byproduct stream may have a viscosity in the range of 1 to 25,000 poise, 100 to 10,000 poise, or 1,000 to 5,000 poise when measured at 10 rad / s and 250°C.

[0153]

[0159] The polyolefin-containing byproduct stream may contain, on a basis of the total weight of the polyolefin-containing byproduct stream 140, at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, at least 2% by weight, at least 2.5% by weight, at least 3% by weight, at least 3.5% by weight, at least 4% by weight, at least 4.5% by weight, at least 5% by weight, at least 8% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 18% by weight, at least 20% by weight, at least 22% by weight, or at least 25% by weight, and / or 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 2% by weight or less of one or more non-reactive solids. Non-reactive solids are solid components that do not chemically react with PET. Examples of non-reactive solids include, but are not limited to, sand, soil, glass, plastic fillers, and combinations thereof.

[0154]

[0160] The polyolefin-containing byproduct stream 140 contains, on a basis of the total weight of the polyolefin-containing byproduct stream 140, one or more fillers in amounts of at least 100 ppm, at least 250 ppm, at least 500 ppm, at least 750 ppm, at least 1,000 ppm, at least 1,500 ppm, at least 2,000 ppm, at least 2,500 ppm, at least 5,000 ppm, at least 7,500 ppm, or at least 1% by weight, at least 1.5% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, or at least 25% by weight, and / or 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less. The polyolefin-containing by-product flow 140 may contain filler in amounts of 100 ppm to 50% by weight, 500 ppm to 10% by weight, or 1,000 ppm to 5% by weight.

[0155]

[0161] Examples of fillers include, but are not limited to, thixotropic agents such as fine silica and clay (kaolin), pigments, colorants, aluminum trihydrate, flame retardants such as bromine, chlorine, boric acid, and phosphorus, inhibitors such as wax-based materials, ultraviolet light absorbers or stabilizers, conductive additives such as metal particles, carbon particles, or conductive fibers, mold release agents such as zinc stearate, wax, and silicone, calcium carbonate, and calcium sulfate.

[0156]

[0162] In one embodiment or in combination with any of the embodiments described herein, the polyolefin-containing by-product stream 140 has a density of at least 0.75 g / cm 3 , at least 0.80 g / cm 3 , at least 0.85 g / cm 3 , at least 0.90 g / cm 3 , at least 0.95 g / cm 3 , or at least 0.99 g / cm 3 , and / or 1.5 g / cm 3 or less, 1.4 g / cm 3 or less, 1.3 g / cm 3 or less, 1.2 g / cm 3 or less, 1.1 g / cm 3 or less, 1.05 g / cm 3 or less, or 1.01 g / cm 3 or less. The density may be 0.80 to 1.4 g / cm 3 , 0.90 to 1.2 g / cm 3 , or 0.95 to 1.1 g / cm 3It may also be the case that, when removed from the non-PET separation compartment 208, the polyolefin-containing byproduct stream 140 has a temperature of at least 200°C, at least 205°C, at least 210°C, at least 215°C, at least 220°C, at least 225°C, at least 230°C, or at least 235°C, and / or a temperature of 350°C or less, 340°C or less, 335°C or less, 330°C or less, 325°C or less, 320°C or less, 315°C or less, 310°C or less, 305°C or less, or 300°C or less. The polyolefin-containing byproduct stream 140 may contain, on a basis of the total weight of the stream, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of components with higher boiling points than the main terephthalyl or DMT.

[0157]

[0163] As will be discussed in more detail herein, all or part of a polyolefin-containing byproduct stream may be introduced into one or more downstream chemical recycling facilities, either alone or in combination with one or more other byproduct streams, streams originating from one or more other downstream chemical recycling facilities, and / or waste plastic streams containing untreated, partially treated, and / or treated mixed plastic waste.

[0158]

[0164] Referring again to Figure 3, the PET-containing stream 138 (containing dissolved PET and its decomposition products) that exits the non-PET separation section 208 (upstream of the reaction section 210) may then be transferred to the reaction section 210, where at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the decomposition of the PET introduced into the reaction section occurs. Depending on the embodiment, the reaction medium in the reaction section 210 may be stirred, and one or more temperature control devices (such as heat exchangers) may be used to maintain the target reaction temperature. In one embodiment or in combination with any embodiment described herein, the target reaction temperature in reaction compartment 210 is at least 50°C, at least 55°C, at least 60°C, at least 65°C, at least 70°C, at least 75°C, at least 80°C, or at least 85°C, and / or 350°C or less, 345°C or less, 340°C or less, 335°C or less, 330°C or less, 325°C or less, 320°C or less, 315°C or less, 310°C or less, 300°C or less, or 295°C or less, or in the range of 50 to 350°C, 65 to 345°C, or 85 to 335°C.

[0159]

[0165] In one embodiment or in combination with any embodiment described herein, the solvolysis process may be a low-pressure solvolysis process, and the pressure in the solvolysis reactor (or reaction compartment) 210 may be within 5 psi, 10 psi, 15 psi, 20 psi, 25 psi, 30 psi, 35 psi, 40 psi, 45 psi, 50 psi, 55 psi, 75 psi, 90 psi, 100 psi, 125 psi, 150 psi, 200 psi, or 250 psi of atmospheric pressure. The pressure inside the solvolysis reactor (or reaction compartment) 210 may be within 0.35 bar (gauge pressure) of atmospheric pressure, within 0.70 bar, within 1 bar, within 1.4 bar, within 1.75 bar, within 2 bar, within 2.5 bar, within 2.75 bar, within 3 bar, within 3.5 bar, within 3.75 bar, within 5 bar, or within 6.25 bar, and / or 6.9 bar or less, 8.6 bar or less, or 10.35 bar or less. The pressure inside the solvolysis reactor (or reaction compartment) 210 may be at least 100 psig (6.7 barg), at least 150 psig (10.3 barg), at least 200 psig (13.8 barg), at least 250 psig (17.2 barg), at least 300 psig (20.7 barg), at least 350 psig (24.1 barg), at least 400 psig (27.5 barg), and / or 725 psig (50 barg) or less, 650 psig (44.7 barg) or less, 600 psig (41.3 barg) or less, 550 psig (37.8 barg) or less, 500 psig (34.5 barg) or less, 450 psig (31 barg) or less, 400 psig (27.6 barg) or less, or 350 psig (24.1 barg) or less.

[0160]

[0166] In one embodiment or in combination with any embodiment described herein, the solvolysis process carried out in reaction compartment 210 or equipment 30 may be a high-pressure solvolysis process, and the pressure in the solvolysis reactor may be at least 50 barg (725 psig), at least 70 barg (1,015 psig), at least 75 barg (1,088 psig), at least 80 barg (1,161 psig), at least 85 barg (1,233 psig), at least 90 barg (1,307 psig), or at least 95 barg (1,378 psi). g) at least 100 barg (1,451 psig), at least 110 barg (1,596 psig), at least 120 barg (1,741 psig), or at least 125 barg (1,814 psig), and / or 150 barg (2,177 psig) or less, 145 barg (2,104 psig) or less, 140 barg (2,032 psig) or less, 135 barg (1,959 psig) or less, 130 barg (1,886 psig) or less, or 125 barg (1,814 psig) or less.

[0161]

[0167] In one or more embodiments, the solvolysis reaction can be carried out in the presence of at least one acid and / or at least one base in an amount of 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less, based on the total weight of the reactor composition. The solvolysis reaction can be carried out in the presence of a catalyst containing at least one acid and / or at least one base, in an amount of at least 25 ppm by weight, at least 50 ppm by weight, at least 75 ppm by weight, at least 100 ppm by weight, at least 125 ppm by weight, at least 150 ppm by weight, at least 175 ppm by weight, at least 200 ppm by weight, at least 250 ppm by weight, at least 300 ppm by weight, at least 350 ppm by weight, at least 400 ppm by weight, at least 450 ppm by weight, at least 500 ppm by weight, or at least 500 ppm by weight and / or 1,000 ppm by weight or less, based on the total weight of the reaction medium. The reaction may be carried out in the presence of a catalyst containing at least one acid and / or at least one base in amounts of less than or equal to ppm, less than or equal to 900 ppm by weight, less than or equal to 850 ppm by weight, less than or equal to 800 ppm by weight, less than or equal to 750 ppm by weight, less than or equal to 700 ppm by weight, less than or equal to 650 ppm by weight, less than or equal to 600 ppm by weight, less than or equal to 550 ppm by weight, less than or equal to 500 ppm by weight, less than or equal to 450 ppm by weight, less than or equal to 400 ppm by weight, less than or equal to 350 ppm by weight, or less than or equal to 250 ppm by weight, based on the total weight of the reaction medium.

[0162]

[0168] The catalyst system may include a sodium-containing base, a potassium-containing base, or a combination thereof. Suitable acids and bases include, but are not limited to, sodium hydroxide, potassium carbonate, and combinations thereof.

[0163]

[0169] In one embodiment or in combination with any embodiment described herein, the solvolysis (or methanol decomposition) reaction can be carried out in the presence of at least one catalyst. The catalyst may consist of, or be essentially composed of, catalyst metals including manganese, lithium, zinc, titanium, tin, antimony, magnesium, or combinations thereof, or may consist of, or be essentially composed of, catalyst metals including manganese, lithium, or combinations thereof. The catalyst may also include acetates, carbonates, hydroxides, oxides (especially soluble oxides), methoxides, fluorides, chlorides, bromides, iodides, phosphides, sulfates, nitrates of these catalyst metals, and combinations of one or more of these catalyst metals.

[0164]

[0170] The catalyst system may contain one or more catalyst metals (or compounds thereof) alone or in combination with the acids or bases described herein. The catalyst system may contain one or more acids or bases alone. In one embodiment or in combination with any embodiment described herein, the catalyst system may contain catalyst metals in combination with a base such as calcium carbonate or sodium hydroxide.

[0165]

[0171] In one embodiment or in combination with any embodiment described herein, the catalyst may include, consist of, or essentially consist of manganese acetate, lithium acetate, or a combination thereof. For example, the catalyst may include, consist of, or essentially consist of manganese acetate, or may include, consist of, or essentially consist of lithium acetate.

[0166]

[0172] In one embodiment or in combination with any embodiment described herein, the catalyst may not include other typical solvolysis (or methanol decomposition) catalysts such as tin, zinc, and / or titanium, but these catalysts may be present in the solvolysis reactor (or reaction medium or flow withdrawn from the reactor) in amounts of 500 ppm by weight or less, 400 ppm by weight or less, 300 ppm by weight or less, 200 ppm by weight or less, 150 ppm by weight or less, 100 ppm by weight or less, 50 ppm by weight or less, 25 ppm by weight or less, 10 ppm by weight or less, or 5 ppm by weight or less, based on the total feed to the reactor (or the reaction medium or flow as measured in the reactor or withdrawn from the reactor). Unless otherwise defined herein, the weight of the catalyst is determined based on the total weight of the catalyst metal.

[0167]

[0173] The catalyst may be added to the reaction system at one or more of several locations. For example, all or part of the catalyst may be mixed with the waste plastic stream 112 introduced into the solvolysis unit, and / or all or part of the catalyst may be added to the mixing section 206. If added to the mixing section 206, the catalyst may be mixed with the solvent in the stream 212, or added via a separation catalyst line (not shown in Figure 3). In addition or instead, all or part of the catalyst may be added to the reaction medium in the stream exiting the mixing section 206 at line 138 before being introduced into the reactor 210. In some cases, all or part of the catalyst may be added to the reactor 210 via a separate catalyst line (not shown), or via a regeneration line (not shown) between the reactor 210 and the mixing section 206.

[0168]

[0174] In one embodiment or in combination with any embodiment described herein, the reaction medium in the solvorea may include PET and / or its decomposition products including PET oligomers, monomers such as ethylene glycol and dimethyl tephthalate, at least one non-PET plastic (polyolefin, PVC, and other plastics described herein) and / or its decomposition products, a main solvent, and a catalyst comprising manganese acetate and / or lithium acetate.

[0169]

[0175] The catalyst (or one or more components of the catalyst) shall be at least 25 ppm by weight, at least 30 ppm by weight, at least 35 ppm by weight, at least 40 ppm by weight, at least 45 ppm by weight, at least 50 ppm by weight, at least 55 ppm by weight, at least 60 ppm by weight, at least 65 ppm by weight, at least 70 ppm by weight, at least 75 ppm by weight, at least 90 ppm by weight, at least 100 ppm by weight, at least 125 ppm by weight, at least 150 ppm by weight, at least 175 ppm by weight, or at least 200 ppm by weight, and / or 1,000 ppm by weight or less, based on the weight of the feed to the solvolysis reactor 210 (caption ppm per unit weight of feed), It may be present in amounts of 00 ppm by weight or less, 800 ppm by weight or less, 700 ppm by weight or less, 600 ppm by weight or less, 500 ppm by weight or less, 450 ppm by weight or less, 400 ppm by weight or less, 350 ppm by weight or less, 300 ppm by weight or less, 250 ppm by weight or less, 240 ppm by weight or less, 230 ppm by weight or less, 220 ppm by weight or less, 210 ppm by weight or less, 200 ppm by weight or less, 190 ppm by weight or less, 180 ppm by weight or less, or 175 ppm by weight or less (measured as the weight of the catalyst metal), or it may be present in amounts in the range of 25 to 1000 ppm by weight, 50 to 800 ppm by weight, 100 to 600 ppm by weight, 125 to 400 ppm by weight, or 150 to 350 ppm by weight. The catalyst in amounts within the above range may be present in the solvolysis reactor or in the sample of the reaction medium or in the flow removed from the reactor.

[0170]

[0176] The catalyst may be in any suitable form, for example, heterogeneous or homogeneous with the reaction mixture. In one or more embodiments, the catalyst may be mixed with the liquid before (or when) it is added to the solvolysis equipment to provide a liquid-phase catalyst, which is then introduced into the mixing compartment 206 and / or the solvolysis reactor 210. The catalyst may include one or more soluble or partially soluble forms of these metals. The catalyst may be mixed with the solvent before being introduced into the mixing compartment 206.

[0171]

[0177] In one embodiment or in combination with any embodiment described herein, the average residence time of the reaction medium in the reaction compartment 210 may be at least 1 minute, at least 2 minutes, at least 5 minutes, at least 10 minutes, or at least 15 minutes, and / or 12 hours or less, 11 hours or less, 10 hours or less, 9 hours or less, 8 hours or less, 7 hours or less, 6 hours or less, 5 hours or less, or 4 hours or less. At least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the total weight of PET introduced into the solvolysis or methanol decomposition equipment 30 may be decomposed in the reactor outflow 144 when it leaves the reaction compartment 210.

[0172]

[0178] In one embodiment or in combination with any embodiment described herein, the reactor cleanup stream 142 may be removed from the reaction compartment 210 and at least a portion of it may be transferred as a reactor cleanup byproduct stream 142 to one or more downstream facilities within the chemical regeneration facility 10. The reactor cleanup byproduct stream 142 may have a boiling point higher than the boiling point of the main terephthalyl (or DMT in the case of methanol decomposition) produced from the solvolysis facility 30.

[0173]

[0179] In one embodiment or in combination with any embodiment described herein, the reactor cleanup byproduct stream 142 contains, based on the total weight of the stream 142, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of major terephthalyl. If the solvolysis equipment is a methanol decomposition equipment, the reactor purification byproduct stream 142 may contain, on a basis of the total weight of the stream 142, at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of DMT.

[0174]

[0180] In one embodiment or in combination with any embodiment described herein, the reactor cleansing byproduct stream 142 may contain components having a boiling point higher than the boiling point of DMT (or other terephthal) in amounts of 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less. In addition or instead, the reactor cleansing byproduct stream 142 may have a melting temperature at least 5°C, at least 10°C, at least 15°C, at least 20°C, or at least 25°C lower than the reactor temperature, and / or at most 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, 20°C, or 15°C lower than the reactor temperature, or the melting temperature of the byproduct stream 142 may be lower than the reactor temperature by an amount in the range of 5 to 50°C, 10 to 45°C, or 10 to 40°C.

[0175]

[0181] Furthermore, the reactor purification byproduct stream 142 may contain at least 100 ppm and 25% by weight or less of one or more non-terephthalyl solids based on the total weight of the stream 142. In one embodiment or in combination with any embodiment described herein, the total amount of non-terephthalyl solids in the reactor purification byproduct stream 142 is at least 150 ppm, at least 200 ppm, at least 250 ppm, at least 300 ppm, at least 350 ppm, at least 400 ppm, at least 500 ppm, at least 600 ppm, at least 700 ppm, at least 800 ppm, at least 900 ppm, at least 1,000 ppm, at least 1,500 ppm, at least 2,000 ppm, at least 2,500 ppm, and at least 3,000 ppm based on the total weight of the stream. pm, may be at least 3,500 ppm, at least 4,000 ppm, at least 4,500 ppm, at least 5,000 ppm, at least 5,500 ppm, at least 6,000 ppm, at least 7,000 ppm, at least 8,000 ppm, at least 9,000 ppm, at least 10,000 ppm, or at least 12,500 ppm, and / or 25% by weight or less, 22% by weight or less, 20% by weight or less, 18% by weight or less, 15% by weight or less, 12% by weight or less, 10% by weight or less, 8% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less.

[0176]

[0182] In one embodiment or in combination with any embodiment described herein, the reactor cleanup byproduct stream 142 contains, on a basis of the total weight of this stream, at least 100 ppm by weight, at least 250 ppm by weight, at least 500 ppm by weight, at least 750 ppm by weight, at least 1,000 ppm by weight, at least 1,500 ppm by weight, at least 2,000 ppm by weight, at least 2,500 ppm by weight, at least 3,000 ppm by weight, at least 3,500 ppm by weight, at least 4,000 ppm by weight, at least 4,500 ppm by weight, at least 5,000 ppm by weight, at least 5,500 ppm by weight, at least 6,000 ppm by weight, at least 6,500 ppm by weight, and at least 7,000 ppm by weight. Having a total solid content of 0 ppm by weight, at least 7,500 ppm by weight, at least 8,000 ppm by weight, at least 8,500 ppm by weight, at least 9,000 ppm by weight, at least 9,500 ppm by weight, or at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 8% by weight, at least 10% by weight, or at least 12% by weight, and / or 25% by weight or less, 22% by weight or less, 20% by weight or less, 17% by weight or less, 15% by weight or less, 12% by weight or less, 10% by weight or less, 8% by weight or less, 6% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or 7,500 ppm by weight or less, 5,000 ppm by weight or less, or 2,500 ppm by weight or less.

[0177]

[0183] Examples of solids include, but are not limited to, non-volatile catalyst compounds. In one embodiment or in combination with any embodiment described herein, the reactor cleansing byproduct stream has a concentration of at least 100 ppm, at least 250 ppm, at least 500 ppm, at least 750 ppm, at least 1,000 ppm, at least 1,500 ppm, at least 2,000 ppm, at least 2,500 ppm, at least 3,000 ppm, at least 3,500 ppm, at least 4,000 ppm, and at least 4,500 ppm. It may also contain a non-volatile catalyst metal in amounts of at least 5,000 ppm, at least 7,500 ppm, at least 10,000 ppm, or at least 12,500 ppm, and / or 60,000 ppm or less, 50,000 ppm or less, 40,000 ppm or less, 35,000 ppm or less, 30,000 ppm or less, 25,000 ppm or less, 20,000 ppm or less, 15,000 ppm or less, or 10,000 ppm or less.

[0178]

[0184] Examples of suitable non-volatile catalyst metals include, but are not limited to, titanium, zinc, manganese, lithium, magnesium, sodium, methoxide, alkali metals, alkaline earth metals, tin, residual esterification or transesterification catalysts, residual polycondensation catalysts, aluminum, depolymerization catalysts, and combinations thereof. As will be described in further detail herein, all or part of the reactor cleanup byproduct stream 142 may be introduced into one or more downstream chemical recycling facilities, either alone or in combination with one or more other byproduct streams, streams originating from one or more other downstream chemical recycling facilities, and / or waste plastic streams including untreated, partially treated, and / or treated mixed plastic waste.

[0179]

[0185] When drawn out of the reaction compartment and / or introduced into one or more downstream facilities, the temperature of the reactor cleansing byproduct stream 142 may be at least 130°C, at least 135°C, at least 140°C, at least 145°C, at least 150°C, at least 155°C, at least 160°C, at least 165°C, at least 170°C, at least 175°C, at least 180°C, at least 185°C, at least 190°C, at least 195°C, at least 200°C, at least 205°C, at least 210°C, at least 215°C, at least 220°C, at least 225°C, at least 230°C, at least 245°C, at least 250°C, at least 255°C, at least 260°C, at least 265°C, at least 270°C, at least 275°C, at least 280°C, at least 285°C, at least 290°C, at least 295°C, at least 300°C, at least 325°C, or at least 350°C.

[0180]

[0186] In one embodiment or in combination with any embodiment described herein, as generally shown in Figure 3, the effluent 144 from the reaction compartment 210 in the solvolysis apparatus 30 may be sent via a non-PET separation compartment 208 located downstream of the reactor, as previously stated, if necessary. The effluent 144 from the reactor or, if present, the non-PET separation compartment 208, is transferred to the product separation compartment 220, where at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of heavy organic material is separated from the feed stream 144, forming a stream 146 mainly of light organic material and a heavy organic material stream 148. Optionally suitable methods can be used for separating these streams, including, for example, distillation, extraction, decantation, crystallization, membrane separation, solid-liquid separation such as filtration (e.g., belt filter), and combinations thereof. The resulting heavy organic and light organic materials may be sent to a downstream separation section for further purification and / or recovery of the desired final product and by-products.

[0181]

[0187] As shown in Figure 3, a heavy organic flow 148, which may contain, for example, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% heavy organic components on a basis of the total weight of the flow drawn from the product separation section 220, may be introduced into the heavy organic separation section 240. In the heavy organic separation section 240, the main terephthalyl product flow 158 may be separated from the terephthalyl column bottom or the "sludge" byproduct flow 160. Such separation may be achieved, for example, by distillation, extraction, decantation, membrane separation, melt crystallization, section purification, and combinations thereof. As a result, a flow 158 is obtained in which, on a basis of the total weight of the flow, the main terephthalyl (or DMT) is present in an amount of at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99%. In one embodiment or in combination with any embodiment described herein, at least some or all of the main terephthalyl may include a regenerated terephthalyl component (regenerated terephthalyl), for example, a regenerated DMT component (regenerated DMT).

[0182]

[0188] Furthermore, the terephthalyl bottom byproduct stream (also called "terephthalyl column bottom byproduct stream," "terephthalyl sludge byproduct stream," or "terephthalyl waste byproduct stream") is extracted from the heavy organic matter separation section 240. If the solvolysis equipment is a methanol decomposition equipment, the stream may also be called the DMT bottom byproduct stream, DMT column bottom byproduct stream, DMT sludge byproduct stream, or DMT waste stream.

[0183]

[0189] In one embodiment or in combination with any embodiment described herein, the byproduct stream may contain oligomers containing solvolytically decomposed polyester moieties in a total weight basis of a composition such as a PET oligomer, for example, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, at least 97%, at least 98%, at least 99%, or at least 99.5%. As used herein, the terms “polyester moiety” or “polyester portion” refer to a polyester moiety or residue, or a reaction product of a polyester moiety or residue. These oligomers may have a number-average chain length of at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, or at least 8 monomer units (acids and glycols) and / or 30 or less, 27 or less, 25 or less, 22 or less, 20 or less, 17 or less, 15 or less, 12 or less, or 10 or less monomer units (acids and glycols), and may include a portion treated with polyester (e.g., PET).

[0184]

[0190] The terephthalyl bottom byproduct flow 160 may contain, on a basis of the total weight of the flow, at least 0.01% by weight, at least 0.05% by weight, at least 0.10% by weight, at least 0.50% by weight, at least 1% by weight, or at least 1.5% by weight, and / or 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 2% by weight or less of non-oligomer components. Such components may be present in amounts ranging from 0.01 to 40% by weight, 0.05 to 35% by weight, or 1.5 to 10% by weight, on a basis of the total weight of the flow.

[0185]

[0191] In one embodiment or in combination with any embodiment described herein, the oligomer further comprises at least one ester other than dimethyl terephthalate, at least one carboxylic acid other than terephthalic acid or DMT, and / or at least one glycol other than ethylene glycol. For example, the oligomers include diethylene glycol, triethylene glycol, 1,4-cyclohexanedimethanol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, neopentyl glycol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4), 2,2,4-trimethylpentanediol-(1,3), 2-ethylhexanediol-(1,3), 2,2-diethylpropanediol-(1,3), hexanediol-(1,3), 1,4-di(hydroxyethoxy)benzene, 2,2-bis-(4-hydroxycyclohexyl)propane, and 2,4-dihydroxy-1,1,3,3-tetramethyl-cyclo It may contain one or more parts of butane, 2,2,4,4-tetramethylcyclobutanediol, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, isosorbide, hydroquinone, BDS-(2,2-(sulfonylbis)-4,1-phenyleoxy))bis(ethanol), phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, diphenyl-3,4'-dicarboxylic acid, neopentyl glycol, 1,4-cyclohexanedicarboxylic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, and combinations thereof.

[0186]

[0192] The terephthalyl bottom byproduct stream may also contain DMT in amounts of at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95%, and / or 99% or less, 95% or less, 90% or less, 85% or less, 80% or less, 75% or less, 70% or less, 65% or less, 60% or less, 55% or less, 50% or less, 45% or less, or 40% or less, based on the total weight of the byproduct stream. Other examples of major glycols that may be considered (depending on the PET or other polymer being processed) include, but are not limited to, diethylene glycol, neopentyl glycol, 1,4-cyclohexanedimethanol, and 2,2,4,4-tetramethyl-1,3-cyclobutanediol.

[0187]

[0193] In one embodiment or in combination with any embodiment described herein, the terephthalyl column bottom (or DMT column bottom) byproduct stream 160 may contain oligomers and at least one substituted terephthalyl component. As used herein, the term "substituted terephthalyl" means a terephthalyl component having at least one substituted atom or group. The terephthalyl bottom byproduct stream 160 may contain, on a basis of the total weight of the terephthalyl bottom byproduct stream 160, at least 1 ppb by weight, at least 100 ppb by weight, at least 500 ppb by weight, or at least 1 ppm by weight, at least 50 ppm by weight, at least 1,000 ppm by weight, at least 2,500 ppm by weight, at least 5,000 ppm by weight, at least 7,500 ppm by weight, at least 10,000 ppm by weight, at least 1% by weight, at least 2% by weight, or at least 5% by weight, and / or 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, 0.1% by weight or less, or 0.01% by weight or less of substituted terephthalyl components.

[0188]

[0194] As described in further detail herein, all or part of the terephthalyl bottom byproduct stream 160 may be introduced into one or more downstream chemical recycling facilities, either alone or in combination with one or more other byproduct streams, streams originating from one or more other downstream chemical recycling facilities, and / or waste plastic streams containing untreated, partially treated, and / or treated mixed plastic waste.

[0189]

[0195] Referring again to Figure 3, the stream 146, which mainly consists of light organic matter, from the product separation section 220 may be introduced into the light organic matter separation section 230. In the light organic matter separation section 230, this stream 146 may be separated to remove the main solvent (e.g., methanol in methanol-mediated decomposition), and the main glycol (e.g., ethylene glycol in methanol-mediated decomposition) may be separated from organic by-products that are lighter than the main glycol and heavier than the main glycol.

[0190]

[0196] In one embodiment or in combination with any embodiment described herein, the solvent stream 150 withdrawn from the light organic matter separation section 230 may contain at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the main solvent, based on the total weight of the stream 150. If the solvolysis unit 30 is a methanol solvolysis unit, the stream 150 may contain at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of methanol, based on the total weight of the stream. All or part of the stream may be returned to a regeneration process at one or more locations within the solvolysis unit for further use.

[0191]

[0197] In one embodiment or in combination with any embodiment described herein, at least one light organic solvolysis byproduct stream 152 (also called the “light organic” stream) can also be taken out of the light organic separation compartment 230 and may contain at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of components having a boiling point lower than the boiling point of the main terephthalyl (or DMT) (neither the main glycol (or ethylene glycol) nor the main solvent (or methanol)). In addition to or instead of the above, the byproduct stream may contain components having a boiling point higher than that of DMT, such as 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, and 1% by weight or less, and the stream 152 itself may have a boiling point lower than that of the main terephthalyl (or DMT).

[0192]

[0198] In one embodiment, or in combination with any embodiment described herein, the light organic byproduct stream may contain at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, or at least 90% by weight of components having a boiling point lower than the boiling point of the major glycol (or lower than the boiling point of ethylene glycol in the case of methanol-added decomposition of PET).

[0193]

[0199] In one embodiment or in combination with any embodiment described herein, the light organic solvolysis byproduct stream 152 may be produced in a solvolysis facility containing a main solvent (e.g., methanol). For example, the light organic byproduct stream 152 may contain at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, or at least 55% by weight, and / or 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, or 30% by weight or less of a main solvent.

[0194]

[0200] Furthermore, this byproduct flow 152 contains acetaldehyde in amounts of at least 1 ppm, at least 5 ppm, at least 10 ppm, at least 50 ppm, at least 100 ppm, at least 250 ppm, at least 500 ppm, at least 750 ppm, or at least 1,000 ppm, and / or 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, It may contain 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, 0.1% by weight or less, or 0.05% by weight or less, or acetaldehyde may be present in amounts of 1 ppm to 50% by weight, 50 ppm to 0.5% by weight, or 100 ppm to 0.05% by weight, based on the total weight of the by-product flow.

[0195]

[0201] Furthermore, the light organic byproduct flow 152 contains p-dioxane in amounts of at least 1 ppm, at least 5 ppm, at least 10 ppm, at least 50 ppm, at least 100 ppm, at least 250 ppm, at least 500 ppm, at least 750 ppm, or at least 1,000 ppm, and / or 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 3 It may be included in amounts of 5% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, 0.5% by weight or less, 0.1% by weight or less, or 0.05% by weight or less, or p-dioxane may be present in amounts of 1 ppm to 50% by weight, 50 ppm to 0.5% by weight, or 100 ppm to 0.05% by weight, based on the total weight of the byproduct flow.

[0196]

[0202] Light organic byproducts flow 152 include tetrahydrofuran (THF), methyl acetate, silicate, 2,5-methyldioxolane, 1,4-cyclohexanedimethanol, 2-ethyl-1-hexanol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, 2,2,4-trimethyl-3-pentenal, 2,2,4-trimethyl-3-pentenol, 2,2,4-trimethylpentane, 2,4-dimethyl-3-pentanone (DIPK), isobutyl isobutyrate, Methyl formate, n-butanol, acetate, dibutyl ether, heptane, dibutyltetraphthalate, dimethyl phthalate, dimethyl 1,4-cyclohexanedicarboxylate, 1-methoxyethanol, 2-methoxyethanol, 2-methyl-1,3-dioxolane, 1,1-dimethoxy-2-butene, 1,1-dimethoxyethane, 1,3-propanediol, 2,5-dimethyl-1,3,5-hexadiene, 2,5-dimethyl-2,4-hexadiene, α-methyl The material may further contain at least one additional component selected from the group consisting of styrene, diethylene glycol methyl ether, diethylene glycol formal, dimethoxydimethylsilane, dimethyl ether, diisopropyl ketone, EG benzoate, hexamethylcyclotrisiloxane, hexamethyldisiloxane, methoxytrimethylsilane, 4-ethylmethyl benzoate, methyl caprylate, methyl glycolate, methyl lactate, methyl laurate, methyl methoxyethyl terephthalate, methyl nonanoate, methyl oleate, methyl palmitate, methyl stearate, methyl-4-acetyl benzoate, octamethylcyclotetrasiloxane, styrene, trimethylsilanol, 1,1-dimethoxy-2-butene, 4-methylmorpholine, 1,3,3-trimethoxypropane, methyl myristate, dimethyl adipate, n-methylcaprolactam, dimethyl azelate, neopentyl glycol, and combinations thereof.

[0197]

[0203] In one embodiment or in combination with any embodiment described herein, this additional component is silane, 2,5-methyldioxolane, 2-ethyl-1-hexanol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, 2,2,4-trimethyl-3-pentenal, 2,2,4-trimethyl-3-pentenol, 2,2,4-trimethylpentane, 2,4-dimethyl-3-pentanone (DIPK), isobutyl isobutyrate, methyl formate, n-butanol, dibutyl ether, heptane, dibutyl terephthalate, 1,4-dimethyl cyclohexanedicarboxylate, 1,1-dimethoxy-2-butene, 1,3-propanediol, 2,5-dimethyl-1,3,5-hexadiene, 2,5-dimethyl-2,4-hexadiene, α-methylstyrene, The following can be selected from the group consisting of diethylene glycol formal, dimethoxydimethylsilane, dimethyl ether, diisopropyl ketone, hexamethylcyclotrisiloxane, hexamethyldisiloxane, methoxytrimethylsilane, methyl 4-ethylbenzoate, methyl caproate, methyl lactate, methyl laurylate, methyl methoxyethyl terephthalate, methyl nonanoate, methyl oleate, methyl palmitate, methyl stearate, octamethylcyclotetrasiloxane, styrene, trimethylsilanol, 1,1-dimethoxy-2-butene, 4-methylmorpholine, 1,3,3-trimethoxypropane, methyl myristearate, methyl adipate, n-methylcaprolactam, methyl azelate, neopentyl glycol, and combinations thereof.

[0198]

[0204] In one embodiment or in combination with any embodiment described herein, the additional component can be selected from the group consisting of 2,2,4,4-tetramethyl-1,3-cyclobutanediol, 2,2,4-trimethyl-3-pentenal, 2,2,4-trimethyl-3-pentenol, 2,2,4-trimethylpentane, 2,4-dimethyl-3-pentanone (DIPK), isobutyl isobutyrate, dimethoxydimethylsilane, methoxytrimethylsilane, methylnonanoic acid, methyl oleate, methyl stearate, and combinations thereof.

[0199]

[0205] In one embodiment or in combination with any embodiment described herein, the additional component may be selected from the group consisting of 1,1-dimethoxy-2-butene, 4-methylmorpholine, 1,3,3-trimethoxypropane, methyl myristate, dimethyl adipate, n-methylcaprolactam, dimethyl azelaate, neopentyl glycol, and combinations thereof.

[0200]

[0206] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 has an average boiling point lower than the boiling point of the main solvent (e.g., methanol if the solvolysis equipment is a methanol solvolysis equipment). In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 may have an average boiling point lower than the boiling point of the main glycol (e.g., ethylene glycol for solvolysis of PET).

[0201]

[0207] Now, looking at Figure 4, schematic diagrams of several flows drawn from the light organic matter separation section 230 shown in Figure 3 are shown. In particular, as shown in Figure 4, at least one solvent flow 150, at least one water flow 155, at least one glycol flow 154, and one or more byproduct flows selected from the group consisting of a low boiler flow 190, a solvent azeotrope or intermediate boiler flow 192, a water azeotrope or intermediate boiler flow 194, and a glycol azeotrope or intermediate boiler flow 196 may be taken out of the light organic matter separation section 230. Furthermore, a glycol bottom byproduct flow 156 may also be taken out of the light organic matter separation section 230, as described in detail earlier. Naturally, each of the above flows is named according to the component present in the dominant amount. In other words, the names of the flows used above reflect the main components of the flow that are present in amounts of at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, or at least 85% by weight, based on the total weight of the flow.

[0202]

[0208] As shown in Figure 4, a feed stream 146 may be introduced into the light organic matter separation section 230, which may contain at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, or at least 90% by weight of organic components (excluding DMT) having a boiling point higher than the boiling point of the main terephthalyl (or DMT) component. As shown in Figure 3, this stream 146 may originate from the product separation section and / or reaction section of a solvolysis (or methanol decomposition) plant. The light organic matter separation section 230, as generally shown in Figure 4, may employ any suitable type of separation technique, including, for example, distillation, extraction, decantation, and combinations thereof. Two or more different types of separation techniques may be used in series or in parallel to provide the product and byproduct streams shown in Figure 4.

[0203]

[0209] As shown in Figure 4, the feed stream 146 introduced into the light organic matter recovery section 230 may be separated into one or more further streams, for example, a low-boiling-point stream 190, a solvent azeotrope or intermediate-boiling-point stream 192, a solvent stream 150, a water azeotrope or intermediate-boiling-point stream 194, a water stream 155, a glycol azeotrope or intermediate-boiling-point stream 196, a glycol stream 154, and a glycol bottom stream 156. The light organic byproduct stream 152 taken out from the light organic matter recovery section shown in Figure 3 may contain one or more of these streams individually or in combination. For example, as generally shown in Figure 4, at least two or more streams can be mixed to form the light organic byproduct stream 152. Such mixing can be done, for example, in a light organic byproduct mixing section 232, or one or more streams can simply be mixed in a tank or other apparatus (not shown). In some cases, at least three, at least four, or at least five of the flows shown in Figure 4 can be mixed to form a light organic byproduct flow 152. All or some of these flows, individually or in combination, can be sent to one or more downstream processing or recycling facilities as described herein.

[0204]

[0210] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 may contain at least one azeotrope. As used herein, the term “azeotrope” means a mixture of two or more components that have a constant boiling point when the mixture is boiled. The light organic byproduct stream 152 may contain a component that forms an azeotrope with a major solvent (e.g., methanol), a component that forms an azeotrope with water, and / or a component that forms an azeotrope with a major glycol (e.g., ethylene glycol). If formed, two or more of the azeotropes or azeotrope-containing streams may be mixed to form at least a portion of the light organic byproduct stream 152, or one or more of the azeotropes may be supplied separately to one or more downstream chemical processing facilities shown in Figures 1a and 1b.

[0205]

[0211] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 contains, on a basis of the total weight of the light organic byproduct stream, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, or at least 85% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight or less of a major solvent azeotrope. In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 contains, on a basis of the total weight of the light organic byproduct stream 152, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, or at least 85% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight or less methanol (or other major solvent) azeotrope. In one embodiment or in combination with any embodiment described herein, the light organic flow 152 does not have to be an azeotrope with the main solvent (or methanol), or it may contain such azeotrope in an amount of 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less, based on the total weight of the flow 152.

[0206]

[0212] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 may include an intermediate boiling stream having a boiling point between the boiling point of the low-boiling substance and the boiling point of the main solvent. This stream may contain, on a basis of the total weight of the stream, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, or at least 90% by weight of the component having a boiling point between the boiling point of the low-boiling substance and the boiling point of the main solvent. This may be called a solvent intermediate boiling stream and may not contain a solvent (or methanol) azeotrope, or may contain such a component in an amount of 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less of the component on a basis of the total weight of the stream.

[0207]

[0213] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream contains, on a basis of the total weight of the light organic byproduct stream 152, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, or at least 85% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight of azeotrope water.

[0208]

[0214] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 may include an intermediate boiling point stream having a boiling point between the boiling point of the main solvent (or methanol) and the boiling point of water. This stream may be called an intermediate boiling point water stream and may not contain water azeotropes, or it may contain water azeotropes of 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less, based on the total weight of the stream.

[0209]

[0215] In one embodiment or in combination with any embodiment described herein, the light organic byproduct flow 152 is at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, and at least The flow contains 70% by weight, at least 75% by weight, at least 80% by weight, or at least 85% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight or less of a major glycol (or ethylene glycol) azeotrope, or the azeotrope may be present in amounts ranging from 5 to 99% by weight, 10 to 95% by weight, or 15 to 85% by weight, based on the total weight of the flow.

[0210]

[0216] In one embodiment or in combination with any embodiment described herein, the light organic byproduct flow contains, on a basis of the total weight of the light organic byproduct flow, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, or at least 85% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight or less of azeotropes of ethylene glycol (or another major glycol), or such azeotropes may be present in amounts ranging from 5 to 99% by weight, 10 to 95% by weight, or 15 to 85% by weight, on a basis of the total weight of the flow.

[0211]

[0217] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 may include an intermediate boiling stream having a boiling point between the boiling point of water and the boiling point of the main glycol (or ethylene glycol). This stream may be called a glycol intermediate boiling stream and may not contain glycol (or ethylene glycol) azeotropes, but may contain 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight of glycol azeotropes based on the total weight of the stream.

[0212]

[0218] Furthermore, in one embodiment or in combination with any embodiment described herein, the light organic flow 152 withdrawn from the solvolysis (or methanol solvolysis) equipment contains, on a basis of the total weight of the flow 152, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, or at least 55% by weight, and / or 90% by weight or less. It may also contain a major solvent (or methanol) in an amount of 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, or 30% by weight or less, or the major solvent may be present in an amount ranging from 2 to 90% by weight, 5 to 85% by weight, or 10 to 70% by weight.

[0213]

[0219] Similarly, in one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 taken out of the solvolysis (or methanol solvolysis) equipment may contain, on a basis of the total weight of the stream, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, or at least 55% by weight, and / or 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, or 30% by weight or less of a major glycol (or ethylene glycol), or this major glycol may be present in amounts ranging from 2 to 90% by weight, 5 to 85% by weight, or 10 to 70% by weight. The light organic byproduct flow 152 may contain water in amounts of at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, or at least 30% by weight, and / or 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, or 10% by weight or less, or water may be present in amounts ranging from 2 to 50% by weight, 5 to 45% by weight, or 5 to 65% by weight, based on the total weight of the flow 152.

[0214]

[0220] As described in further detail herein, all or part of the light organic by-product stream 152 (or one or more streams constituting the light organic by-product stream 152) may be introduced into one or more downstream chemical recycling facilities either alone or mixed with one or more other by-product streams, streams from one or more other downstream chemical recycling facilities, and / or waste plastic streams containing untreated, partially treated, or treated mixed plastic waste.

[0215]

[0221] Referring again to Figure 4, the low-boiling-point stream 190 removed from the light organic matter recovery section 230 may primarily consist of components having a boiling point lower than the boiling point of the main solvent (or methanol), and / or a boiling point lower than the boiling point of any low-boiling-point solvent azeotrope, if present. In one embodiment or in combination with any embodiment described herein, the low-boiling-point stream 190 may contain, on a basis of the total weight of the low-boiling-point stream 190, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of components having a boiling point lower than the main solvent.

[0216]

[0222] In one embodiment or in combination with any embodiment described herein, the solvent stream 150 may also be drawn from the light organic matter separation compartment 230 and may contain, on a total weight basis, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 25% by weight, at least 40% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of the main solvent. If the solvolysis equipment is a methanol solvolysis equipment, this stream may contain at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 25% by weight, at least 30% by weight, at least 40% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of methanol. All or part of this stream may be returned to the inlet of the solvolysis equipment for further use and regenerated.

[0217]

[0223] Referring again to Figure 4, in one embodiment or in combination with any embodiment described herein, the water stream 155 may also be removed from the light organic matter recovery section 230 of the solvolysis plant. The water stream 155 may contain at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of water. Depending on the content of organic components in the water stream 155, the water stream may be sent to a downstream water treatment plant before further disposal and / or use, as necessary.

[0218]

[0224] As described in further detail herein, all or part of a light organic byproduct stream may be introduced into one or more downstream chemical recycling facilities, either alone or in combination with one or more other byproduct streams, streams originating from one or more other downstream chemical recycling facilities, and / or waste plastic streams containing mixed plastic waste (untreated, partially treated, or treated).

[0219]

[0225] Furthermore, as shown in Figures 3 and 4, the stream 154 mainly containing major glycols can also be withdrawn from the light organic matter separation section 230. In one embodiment or in combination with any embodiment described herein, the stream 154 of major glycols (such as ethylene glycol) may contain at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of major glycols, based on the total weight of the stream 154. The major glycol stream 154 may also contain regenerating components such that the major glycol product stream 154 has at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of regenerating components, based on the total weight of the stream. The main glycol (or ethylene glycol) may also include recycled glycol (or recycled ethylene glycol).

[0220]

[0226] As shown in Figure 3, the glycol-containing bottom byproduct stream 156 may also be withdrawn from the light organic matter separation section 230. The terms “glycol bottom” or “glycol sludge” (or more specifically, EG bottom or EG sludge in methanol-added decomposition) refer to components having a boiling point (or azeotrope) higher than that of the major glycol but lower than that of the major terephthalyl.

[0221]

[0227] In one embodiment or in combination with any embodiment described herein, the glycol bottom byproduct stream 156 may contain at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of a component having a boiling point higher than the boiling point of the main glycol (e.g., ethylene glycol) and lower than the boiling point of the main terephthalyl. The glycol bottom byproduct stream 156 may also contain 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less of a component having a boiling point lower than the boiling point of the main glycol (e.g., ethylene glycol). The glycol bottom byproduct stream 156 may have a boiling point higher than that of the main glycol (e.g., EG) and lower than that of the main terephthalyl (e.g., DMT).

[0222]

[0228] In one embodiment or in combination with any embodiment described herein, the glycol bottom byproduct stream 156 may contain a major glycol and at least one other glycol. For example, the glycol bottom byproduct stream 156 may contain, on a weight basis of the total weight of the byproduct stream 156, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 5% by weight, or at least 8% by weight, and / or 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 12% by weight or less, or 10% by weight or less of a major glycol (or ethylene glycol). The major glycol (or ethylene glycol) may exist on its own (in a free state) or as a part in other compounds.

[0223]

[0229] Other possible major glycols (depending on processed PET or other polymers) include, but are not limited to, diethylene glycol, triethylene glycol, 1,4-cyclohexanedimethanol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, neopentyl glycol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4), 2,2,4-trimethylpentanediol-(1,3), 2-ethylhexanediol-(1,3), 2,2-diethylpropanediol- Examples include (1,3), hexanediol-(1,3), 1,4-di(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethylcyclobutane, 2,2,4,4-tetramethylcyclobutanediol, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, isosorbide, hydroquinone, BDS-(2,2-(sulfonylbis)4,1-phenyleneoxy)bis(ethanol), and combinations thereof. Other glycols may not be ethylene glycols, but may include ethylene glycols. These glycol moieties may also be present in any oligomer of polyester in this stream or other byproduct streams. Furthermore, other non-terephthalyl and / or non-glycol components may also be present in these streams. Examples of such components include isophthalic acid groups and other acid residues with higher boiling points than the main terephthalyl group.

[0224]

[0230] In one embodiment or in combination with any embodiment described herein, glycols other than the main glycol (or ethylene glycol in the case of methanol-added decomposition) may be present in the glycol bottom byproduct stream 156 in amounts of at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, or at least 75% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, or 35% by weight or less, based on the total weight of glycol in the glycol bottom byproduct stream 156.

[0225]

[0231] In one embodiment or in combination with any embodiment described herein, the weight ratio of at least one glycol other than the main glycol in the glycol bottom byproduct stream 156 to the main glycol is at least 0.5:1, at least 0.55:1, at least 0.65:1, at least 0.70:1, at least 0.75:1, at least 0.80:1, at least 0.85:1, at least 0.90:1, at least 0.95:1, at least 0.97:1, at least 0.99:1, at least 1:1, at least 1.05:1, at least 1.1:1, at least 1.15:1, at least 1.2:1, or at least 1.25:1. Furthermore, or alternatively, the weight ratio of at least one glycol other than the major glycol in the glycol bottom byproduct stream 156 to the major glycol is 5:1 or less, 4.5:1 or less, 4:1 or less, 3.5:1 or less, 3:1 or less, 2.5:1 or less, 2:1 or less, 1.5:1 or less, 1.25:1 or less, 1:1 or less, or in the range of 0.5:1 to 5:1, 0.70:1 to 3:1, or 0.80:1 to 2.5:1.

[0226]

[0232] In one embodiment or in combination with any embodiment described herein, the solvolysis apparatus 30 may generate two or more byproduct streams, and the solvolysis apparatus 30 may include two or more heavy organic byproduct streams, two or more light organic byproduct streams, or a combination of light and heavy organic byproduct streams. All or part of one or more solvolysis byproduct streams (shown as stream 110 in Figures 1a and 1b) may be introduced into at least one of the downstream treatment facilities, for example, a pyrolysis apparatus 60, a cracking apparatus 70, a POX gasification apparatus 50, an energy recovery apparatus 80, and any other apparatus described above.

[0227]

[0233] In one embodiment or in combination with any embodiment described herein, two or more (or some of two or more) solvolysis byproduct streams may be introduced into the same downstream processing facility, or in other cases, two or more (or some of two or more) solvolysis byproduct streams may be introduced into different downstream processing facilities. In some embodiments, at least 90% by weight, at least 95% by weight, at least 97% by weight, at least 99% by weight, or all of a single byproduct stream may be introduced into one downstream facility, and in other embodiments, the stream may be divided into two or more downstream facilities such that 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, or 30% by weight or less of a single byproduct stream is introduced into one of the downstream processing facilities.

[0228]

[0234] Referring again to Figures 1a and 1b, in one embodiment or in combination with any embodiment described herein, at least a portion of at least one solvolysis byproduct stream 110 may be mixed with at least a portion of the PO-enriched plastic stream 114 drawn from the pretreatment equipment 20, as shown in Figures 1a and 1b. The amount of a single byproduct stream 110 (or all byproduct streams if two or more are mixed) in the mixed stream with PO-enriched plastic may vary, based on the total weight of the mixed stream, for example, at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, or at least 50% by weight, and / or 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, or 40% by weight or less. As shown in Figures 1a and 1b, the mixed flow may then be introduced into one or more locations in a chemical regeneration facility, such as the POX gasification facility 50, the pyrolysis facility 60, the cracking facility 70, and / or the energy generation facility 80, and the separation facility, and / or for further sale and / or use, as shown in Figure 1b.

[0229] Liquefaction / Dehalogenation

[0235] As shown in Figures 1a and 1b, the PO-enriched waste plastic stream 114 (when mixed with the solvolysis byproduct stream 110, and when not mixed) may optionally be introduced into a liquefaction section or process before being introduced into one or more downstream treatment facilities. As used herein, the term “liquefaction” section or process means a chemical treatment section or process that liquefies at least a portion of the incoming plastic. The process of liquefying the plastic may include chemical liquefaction, physical liquefaction, or a combination thereof. Exemplary methods for liquefying the polymer introduced into the liquefaction section may include (i) heating / melting; (ii) dissolving in a solvent; (iii) depolymerization; (iv) plasticization, and combinations thereof. Furthermore, one or more of options (i) to (iv) may involve the addition of compounding agents or liquefaction agents that help to promote the liquefaction (reduction of viscosity) of the polymer material. Thus, various viscoelastic modifiers (e.g., solvents, depolymerizers, plasticizers, and admixtures) can be used to enhance the fluidity and / or dispersibility of the liquefied waste plastic.

[0230]

[0236] When added to the liquefaction section 40, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of plastic (usually waste plastic) undergoes a viscosity reduction to provide a flow that is primarily liquid. In some cases, the viscosity reduction can be accelerated by heating (e.g., by adding vapor that comes into direct or indirect contact with the plastic), and in other cases, by combining it with a solvent that can dissolve the plastic. Examples of suitable solvents may include, but are not limited to, alcohols such as methanol or ethanol, glycols such as ethylene glycol, diethylene glycol, triethylene glycol, neopentyl glycol, cyclohexanedimethanol, glycerin, pyrolysis oil, motor oil, and water. As shown in Figures 1a and 1b, the solvent flow 141 can be added directly to the liquefaction section 40 or mixed with one or more flows (not shown in Figures 1a and 1b) supplied to the liquefaction section 40.

[0231]

[0237] In one embodiment or in combination with any embodiment described herein, the solvent may include, for example, a regenerating component solvent having at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of regenerating component material, based on the total weight of the flow. Alternatively, or in addition, the regenerating component of the solvent in line 141 may be 99.9% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 1% by weight or less, based on the total weight of the flow, or it may be in the range of 1 to 99% by weight, 5 to 90% by weight, or 10 to 75% by weight.

[0232]

[0238] The regenerated components may originate from one or more flows within the chemical regeneration facility 10, for example, a solvolysis byproduct flow (e.g., formed from a waste plastics flow containing PET) and / or a pyrolysis oil flow (e.g., formed from a waste plastics flow containing polyolefins and / or from the pyrolysis of byproducts of solvolysis of waste PET). Several examples of flows that can be introduced into the liquefaction section 40 as solvent 141 are shown in Figures 1a and 1b. All or part of each of these flows can be used as a solvent. The solvent flow 141 can be introduced directly into the liquefaction tank of the liquefaction section 40 (not shown in Figures 1a and 1b) separately from the waste plastics flow, so that the mixing of the solvent and waste plastics takes place in the liquefaction tank, and / or the solvent can be mixed with one or more flows introduced into the liquefaction section 40 so that the mixed flow is introduced into the liquefaction tank of the liquefaction section 40.

[0233]

[0239] In one embodiment or in combination with any embodiment described herein, the solvent may include a stream taken from one or more other pieces of equipment within the chemical regeneration facility. For example, the solvent may include a stream taken from at least one of the solvolysis equipment 30, the pyrolysis equipment 60, and the cracking equipment 70. The solvent may be at least one of the solvolysis by-products described herein, or it may be pyrolysis oil, or it may be pyrolysis oil.

[0234]

[0240] In some cases, plastics can be depolymerized by contact with a depolymerizing agent, for example, by shortening the number-mean-chain length of the plastic. In one embodiment or in combination with any embodiment described herein, at least one of the solvents listed above can be used as a depolymerizing agent, and in one or more other embodiments, the depolymerizing agent may be an organic acid (e.g., acetic acid, citric acid, butyric acid, formic acid, lactic acid, oleic acid, oxalic acid, stearic acid, tartaric acid, and / or uric acid), or an inorganic acid such as sulfuric acid (in the case of polyolefins). The depolymerizing agent can lower the melting point and / or viscosity of the polymer by shortening the number-mean-chain length of the polymer.

[0235]

[0241] Alternatively, or in addition to the above, plasticizers may be used in the liquefaction section to reduce the viscosity of the plastic. Examples of plasticizers for polyethylene include dioctyl phthalate, dioctyl terephthalate, glyceryl tribenzoate, polyethylene glycol with a molecular weight of up to 8,000 daltons, sunflower oil, paraffin wax with a molecular weight of 400 to 1,000 daltons, paraffinic oils, mineral oil, glycerin, EPDM, and EVA. Examples of plasticizers for polypropylene include dioctyl sebacate, paraffinic oils, isooctyl tolate, plasticizing oil (Draqual 34), naphthenic and aromatic treated oils, and glycerin. Examples of plasticizers for polyesters include polyalkylene ethers having molecular weights in the range of 400 to 1,500 daltons (e.g., polyethylene glycol, polytetramethylene glycol, polypropylene glycol, or mixtures thereof), glyceryl monostearate, octyl epoxy soybean ate, epoxidized soybean oil, tall oil ester epoxy, epoxidized linseed oil, polyhydroxyalkanoates, glycols (e.g., ethylene glycol, pentamethylene glycol, hexamethylene glycol, etc.), phthalates, terephthalates, trimellitates, and polyethylene glycol di(2-ethylhexoate). When used, the plasticizer may be present in amounts of at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, or at least 5% by weight, and / or 10% by weight or less, 8% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less, based on the total weight of the flow, or in the range of 0.1 to 10% by weight, 0.5 to 8% by weight, or 1 to 5% by weight, based on the total weight of the flow.

[0236]

[0242] Furthermore, one or more methods for liquefying waste plastic streams may include adding at least one admixture to the plastics before, during, or after the liquefaction process. Such admixtures may include, for example, emulsifiers and / or surfactants, and can play a role in completely mixing the liquefied plastics into a single phase, particularly when multiple liquid or semi-liquid phases are formed due to density differences between the plastic components of the mixed plastic stream. When used, the admixture may be present in amounts of at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 2% by weight, or at least 5% by weight, and / or 10% by weight or less, 8% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less, based on the total weight of the stream, or in the range of 0.1 to 10% by weight, 0.5 to 8% by weight, or 1 to 5% by weight.

[0237]

[0243] Generally, as shown in Figures 1a and 1b, when mixed with the PO-enriched waste plastics stream 114, the solvolysis byproducts stream 110 (which may contain one or more solvolysis byproducts as described herein) may be added before introducing the PO-enriched waste plastics stream 114 into the liquefaction compartment 40 (as shown by line 113) and / or after removing the liquefied plastics stream from the liquefaction compartment 40 (as shown by line 115). In one embodiment or in combination with any embodiment described herein, at least some or all of the one or more byproduct streams may be introduced directly into the liquefaction compartment as shown in Figures 1a and 1b. In one embodiment or in combination with any embodiment described herein, at least some of the PO-enriched waste plastics stream 114 may be routed completely around the liquefaction compartment 40 via line 117 and, if necessary, mixed with at least one solvolysis byproducts stream 110 as also shown in Figures 1a and 1b.

[0238]

[0244] Furthermore, as shown in Figures 1a and 1b, a portion of the pyrolysis oil stream 143 drawn from the pyrolysis equipment 60 can be mixed with the PO-enriched plastic stream 114 to form liquefied plastic. Although it is shown to be introduced directly into the liquefaction section 40, all or part of the pyrolysis oil stream 143 can be mixed with the PO-enriched plastic stream 114 before introduction into the liquefaction section 40, or after the PO-enriched plastic stream 114 has left the liquefaction section 40. When used, the pyrolysis oil can be added alone or in combination with one or more other solvent streams at one or more locations as described herein.

[0239]

[0245] In one embodiment or in combination with any embodiment described herein, the feed stream from the liquefaction section 40 to one or more of the downstream chemical regeneration treatment facilities may include one or more solvolysis byproduct streams in an amount of at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight, based on the total weight of the feed stream introduced into one or more downstream treatment facilities.

[0240]

[0246] For example, the feed streams 116, 118, 120, and 122 to each of the POX equipment 50, pyrolysis equipment 60, cracking equipment 70, energy recovery equipment 80, and / or other equipment 90 of the chemical recycling facility 10 may contain PO-enriched waste plastics and a predetermined amount of one or more solvolysis by-products described herein. One or more of flows 116, 118, 120, and 122 may contain, on a basis of the total weight of flows 116, 118, 120, and / or 122, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less, or one or more solvolysis byproduct flows of 1% by weight or less. These amounts can apply to a single flow or a combination of two or more of these flows.

[0241]

[0247] Alternatively, or in addition, the liquefied (or viscosity-reduced) plastic flow drawn from the liquefaction section 40 shall be at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight, and / or 95% or less by weight, 90% or less by weight, 85% or less by weight, 80% or less by weight, 75% or less by weight. It may contain PO in amounts of 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight, and the amount of PO may be in the range of 1 to 95% by weight, 5 to 90% by weight, or 10 to 85% by weight, based on the total weight of the flow.

[0242]

[0248] In one embodiment or in combination with any embodiment described herein, the liquefied plastic stream may be a molten plastic stream or may contain plastic dissolved in a liquid solvent. As used herein, the term “dissolved” means at least partially decomposed by chemical and / or physical mechanisms.

[0243]

[0249] In one embodiment or in combination with any embodiment described herein, the liquefied plastic flow exiting the liquefaction compartment 40 is measured with a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / s and a temperature of 350°C to have a porosity of less than 3,000 poises, less than 2,500 poises, less than 2,000 poises, less than 1,500 poises, less than 1,000 poises, and 800 poises. It may have a viscosity of less than 1 poise, less than 750 poise, less than 700 poise, less than 650 poise, less than 600 poise, less than 550 poise, less than 500 poise, less than 450 poise, less than 400 poise, less than 350 poise, less than 300 poise, less than 250 poise, less than 150 poise, less than 100 poise, less than 75 poise, less than 50 poise, less than 25 poise, less than 10 poise, less than 5 poise, or less than 1 poise. In one embodiment or in combination with any embodiment described herein, the viscosity of the liquefied plastic flow exiting the liquefaction section (measured at 350°C and 10 rad / s and expressed in poise) is 95% or less, 90% or less, 75% or less, 50% or less, 25% or less, 10% or less, 5% or less, or 1% or less of the viscosity of the PO-enriched flow introduced into the liquefaction section 40.

[0244]

[0250] As shown in Figure 5, at least one solvolysis byproduct stream 110 and a non-PET waste plastic stream (e.g., PO enrichment stream) 114 may be supplied to the liquefaction section 40. The solvolysis byproduct stream 110 introduced into the liquefaction section 40 may include one or more of the polyolefin-containing byproduct streams, reactor purification byproduct streams, light organic byproduct streams, terephthalyl sludge byproduct streams, and glycol sludge byproduct streams originating from the solvolysis (or methanol decomposition) equipment described above. The solvolysis byproduct stream 110 introduced into the liquefaction section 40 may include at least one, at least two, at least three, at least four, or at least some of all of these streams, which are mixed before or within the liquefaction section 40. The supply to the liquefaction compartment 40 (whether a single flow or a mixed flow) may include at least one solvolysis byproduct flow that is at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, or at least 75% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, or 50% by weight or less, based on the total weight of one or more supply flows.

[0245]

[0251] In one embodiment or in combination with any embodiment described herein, the feed to the liquefaction section 40 may include non-PET plastics such as waste plastics in amounts of at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, or at least 75% by weight, and / or 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, or 50% by weight or less, based on the total weight of one or more feed streams. The waste plastics may mainly consist of polyolefins such as polyethylene and / or polypropylene removed from a pretreatment facility as shown in Figures 1a and 1b. Such flows may contain, on a basis of the total weight of one or more flows, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of polyolefin. Alternatively, such streams may contain, on a basis of the total weight of one or more streams, 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, or 15% by weight or less of polyolefin.

[0246]

[0252] Non-PET waste plastics may further contain PET in amounts of at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, or at least 40% by weight, and / or 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 7% by weight or less, or 5% by weight or less, on a basis of the total weight of one or more flows.

[0247]

[0253] In one embodiment or in combination with any embodiment described herein, the weight ratio of the mixed waste plastic to the solvolysis byproduct stream is at least 0.75:1, at least 0.90:1, at least 1:1, at least 1.5:1, at least 2:1, at least 3:1, at least 4:1, at least 5:1, at least 6:1, at least 7:1, at least 8:1, at least 9:1, at least 10:1, at least 11:1, at least 12:1, at least 13:1, at least 14:1, at least 15:1, at least 16:1, at least 17:1, at least 18:1, at least 19:1, or at least 20:1, and / or 100:1 or less, 75:1 or less, 70:1 or less, 65:1 or less, 60:1 or less, 50:1 or less, 45:1 or less, 40:1 or less, 35:1 or less, 30:1 or less, 25:1 or less, 20:1 or less, or 15:1 or less, or in the range of 0.75:1 to 100:1, 1:1 to 50:1, or 1.5:1 to 20:1.

[0248]

[0254] As shown in Figure 5, at least one primarily vapor stream 164 and at least one primarily liquid stream 161 may be drawn from the liquefaction section 40. In one embodiment or in combination with any embodiment described herein, at least a portion of the vapor stream 164 may be sent, if necessary, to a cleaning device 440, such as a caustic or amine cleaning device, which may employ a cleaning fluid to remove all or some of undesirable components such as chlorine and other halogens, as well as sulfur, carbon dioxide, aldehydes, and combinations thereof. The cleaning device 440 may remove at least 10% by weight, at least 20% by weight, at least 30% by weight, at least 40% by weight, at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, or at least 95% by weight of one or more undesirable components introduced into the cleaning device, based on the total amount of undesirable components introduced into the cleaning device 440.

[0249]

[0255] The resulting steam flow 164 may then be introduced into one or more of the following: an energy recovery unit, a POX gasification unit, and a cracking unit. If necessary, at least a portion of the flow introduced into the POX gasification unit and / or the cracking unit may be mixed with a pyrolysis oil flow (or pyrolysis gas, not shown), and this mixed flow may be introduced into downstream equipment. Depending on the embodiment, the mixed flow may contain, on a basis of the total weight of the flow, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, or at least 50% by weight, and / or 99% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight or less of liquefied steam. Alternatively, or in addition, the mixed flow may contain, on a basis of the total weight of the flow, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, or at least 40% by weight, and / or 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, or 50% by weight or less of pyrolysis oil. In one embodiment or in combination with any embodiment described herein, at least a portion of the vapor flow may be cooled and / or compressed (in a compressor 450 as shown in Figure 1b) before being introduced into one or more downstream processing facilities.

[0250]

[0256] Furthermore, as shown in Figure 5, the flow 161, which is mainly liquid, taken out from the liquefaction section 40 may be introduced into at least one of the following: (i) a POX gasification unit, (ii) an energy recovery unit, and (iii) a pyrolysis unit. In one embodiment or in combination with any embodiment described herein, the flow, which is mainly liquid, may be introduced into at least one, at least two, or all three units, either alone or in combination with one or more other fluids, as detailed herein.

[0251]

[0257] Figure 6 shows the basic components of a liquefaction system that may be used as a liquefaction section 40 in the chemical regeneration facility illustrated in Figures 1a and 1b. Naturally, Figure 6 depicts one exemplary embodiment of the liquefaction system. Certain components depicted in Figure 6 may be omitted, and / or additional components described elsewhere in this specification may be added to the system depicted in Figure 6.

[0252]

[0258] As shown in Figure 6, the waste plastic feed, such as the PO-enriched waste plastic stream 114, may be obtained from a waste plastic feed source, such as the pretreatment equipment 20 described herein. The waste plastic feed, such as the PO-enriched waste plastic stream 114, may be introduced into the liquefaction section 40 (Figure 6 depicts a system including at least one melting tank 310, at least one circulation pump 312, at least one external heat exchanger 340, at least one stripping tower 330, and at least one dissociation vessel 320). These various exemplary components and their functions in the liquefaction section 40 will be described in more detail below.

[0253]

[0259] In one embodiment or in combination with any embodiment described herein, and as shown in Figure 6, the liquefaction section 40 includes a melting tank 310 and a heater. The melting tank 310 receives a waste plastic feed, such as a PO-enriched waste plastic stream 114, and the heater heats the waste plastic. In one embodiment or in combination with any embodiment described herein, the melting tank 310 may include one or more continuous stirring tanks. If one or more viscoelastic modifiers (e.g., solvents, depolymerizers, plasticizers, admixtures) are used in the liquefaction section, such viscoelastic modifiers may be added to and / or mixed with the PO-enriched plastic in or before the melting tank 310.

[0254]

[0260] In one embodiment or in combination with any embodiment described herein, the heater of the liquefaction compartment 40 (not shown in Figure 6) may take the form of an internal heat exchange coil located inside the melting tank 310, an external cover of the melting tank 310, heating wiring outside the melting tank 310, and / or an electric heating element outside the melting tank 310. Alternatively, as shown in Figure 6, the heater of the liquefaction compartment 40 may include an external heat exchanger 340 that receives the liquefied plastic flow 171 from the melting tank 310, heats it, and returns at least a portion of the heated liquefied plastic flow 173 to the melting tank 310.

[0255]

[0261] As shown in Figure 6, when heat is supplied to the liquefaction section 40 using an external heat exchanger 340, a circulation path can be employed to continuously apply heat to the PO-enriched material. In one embodiment or in combination with any embodiment described herein, the circulation path includes a melting tank 310, an external heat exchanger 340, a conduit indicated by line 171 connecting the melting tank and the external heat exchanger, and a pump 151 for circulating the liquefied waste plastic within the circulation path. When a circulation path is employed, the manufactured liquefied PO-enriched material can be continuously taken out of the liquefaction section 40 as part of the PO-enriched flow circulating through conduit 161 shown in Figure 6.

[0256]

[0262] In one embodiment or in combination with any embodiment described herein, the liquefaction compartment 40 may optionally include a device for removing halogens from the PO-enriched material. When the PO-enriched material is heated in the liquefaction compartment 40, halogen-enriched gas may be generated. By dissociating the generated halogen-enriched gas from the liquefied PO-enriched material, the concentration of halogens in the PO-enriched material can be reduced.

[0257]

[0263] In one embodiment or in combination with any embodiment described herein, dehalogenation can be accelerated by blowing a stripping gas (e.g., a flow) into the liquefied PO-enriched material either in the molten tank 310 or elsewhere in the circulation path. As shown in Figure 6, the stripper 330 and the dissociation vessel 320 can be located in the circulation path downstream of the external heat exchanger 340 and upstream of the molten tank 310. As shown in Figure 6, the stripper 330 can receive the heated liquefied plastic flow 173 from the external heat exchanger 340 and provide the blowing of the stripping gas 153 into the liquefied plastic. When the stripping gas 153 is blown into the liquefied plastic, a two-phase medium can be generated in the stripper 330.

[0258]

[0264] The two-phase medium, introduced into the dissociation vessel 320 via flow 175, can then pass through the dissociation vessel 320 (for example, by gravity), where the halogen-enriched gas phase dissociates from the halogen-poor liquid phase and is removed from the dissociation vessel 320 via flow 162. Alternatively, as shown in Figure 6, a portion of the heated liquefied plastic 173 from the external heat exchanger 340 may bypass the stripper 330 and be introduced directly into the dissociation vessel 320.

[0259]

[0265] In one embodiment or in combination with any embodiment described herein, a first portion of the halogen-poor liquid phase discharged from the outlet of the dissociation vessel can be returned to the molten tank 310 via line 159, and a second portion of the halogen-poor liquid phase can be discharged from the liquefaction section as a dehalogenated and liquefied PO-enriched product flow 161. The dissociated halogen-enriched gas flow 162 from the dissociation vessel and the dissociated halogen-enriched gas flow from the molten tank 310 via line 164 can be removed from the liquefaction section 40 for further processing and / or disposal.

[0260]

[0266] In one embodiment or in combination with any embodiment described herein, the dehalogenated and liquefied waste plastic stream 161 leaving the liquefaction section 40 may have a halogen content of less than 500 ppm by weight, less than 400 ppm by weight, less than 300 ppm by weight, less than 200 ppm by weight, less than 100 ppm by weight, less than 50 ppm by weight, less than 10 ppm by weight, less than 5 ppm by weight, less than 2 ppm by weight, less than 1 ppm by weight, less than 0.5 ppm by weight, or less than 0.1 ppm by weight. The halogen content of the liquefied plastic stream 161 leaving the liquefaction section 40 is 95% by weight or less, 90% by weight or less, 75% by weight or less, 50% by weight or less, 25% by weight or less, 10% by weight or less, or 5% by weight or less of the halogen content of the PO-enriched stream introduced into the liquefaction section.

[0261]

[0267] In one embodiment or in combination with any embodiment described herein, the dehalogenated liquefied waste plastic stream 161 leaving the liquefaction section 40 may have a halogen content of less than 500 ppm by weight, less than 400 ppm by weight, less than 300 ppm by weight, less than 200 ppm by weight, less than 100 ppm by weight, less than 50 ppm by weight, less than 10 ppm by weight, less than 5 ppm by weight, less than 2 ppm by weight, less than 1 ppm by weight, less than 0.5 ppm by weight, or less than 0.1 ppm by weight. The halogen content of the liquefied plastic stream 161 leaving the liquefaction section 40 is 95% by weight or less, 90% by weight or less, 75% by weight or less, 50% by weight or less, 25% by weight or less, 10% by weight or less, or 5% by weight or less of the halogen content of the PO-enriched stream introduced into the liquefaction section.

[0262] pyrolysis

[0268] In one embodiment or in combination with any embodiment described herein, the chemical recycling facility 10 schematically depicted in Figures 1a and 1b may include a pyrolysis facility. As used herein, “pyrolysis” means the thermal decomposition of one or more organic materials at high temperatures in an inert (i.e., substantially oxygen-free) atmosphere. A “pyrolysis facility” is a facility that includes all the equipment, lines, and control units necessary for the thermal decomposition of waste plastics and derived raw materials.

[0263]

[0269] FIG. 7 depicts an exemplary pyrolysis facility 60 that converts a waste plastic stream 116, such as liquefied waste plastic from a liquefaction section, into pyrolysis gas, pyrolysis oil, and pyrolysis residues. As is natural, FIG. 7 depicts an exemplary aspect of the present technology. Therefore, specific configurations depicted in FIG. 7 may be omitted, and / or additional configurations described elsewhere in this specification may be added to the system depicted in FIG. 7.

[0264]

[0270] In one aspect or in combination with any aspect described herein, the feed stream 116 to the pyrolysis facility 60 may include at least one of (i) at least one solvolysis by-product stream as described above, and (ii) a PO-enriched stream of waste plastic. One or more of these streams may be continuously or intermittently introduced into the pyrolysis facility 60. When there are multiple types of feed streams, each may be introduced separately, or all or some of the streams may be mixed and the mixed stream introduced into the pyrolysis facility 60. Mixing, if performed, may be continuous or batch. The feed introduced into the pyrolysis facility 60 may be in the form of liquefied plastic (e.g., plastic liquefied, melted, plasticized, depolymerized, or a combination thereof), plastic pellets or particles, or a slurry thereof.

[0265]

[0271] Generally and as also depicted in FIG. 7, the pyrolysis facility 60 includes a pyrolysis reactor 510 and a separator 520 that separates the product stream from the reactor. Although not depicted in FIG. 7, the separator 520 of the pyrolysis facility 60 may include various types of equipment including, but not limited to, a filter system, a multi-stage separator, a condenser, and / or a quench tower.

[0266]

[0272] In the pyrolysis reactor 510, at least a portion of the feed may undergo a pyrolysis reaction to produce a pyrolysis effluent comprising pyrolysis oil, pyrolysis gas, and pyrolysis residues. As used herein, the term "pyrolysis gas" means a composition obtained by pyrolysis that is gaseous at 25 °C and 1 atmosphere. As used herein, the term "pyrolysis oil" means a liquid composition obtained by pyrolyzing at 25 °C and 1 atmosphere. As used herein, the term "pyrolysis residues" means a composition obtained by pyrolysis that is neither pyrolysis gas nor pyrolysis oil and mainly comprises pyrolysis carbon and pyrolysis heavy wax. As used herein, the term "pyrolysis carbon" means a carbon-containing composition obtained by pyrolysis that is solid at 200 °C and 1 atmosphere. As used herein, the term "pyrolysis heavy wax" means, among hydrocarbons having 20 or more carbon atoms obtained by pyrolysis, those other than pyrolysis carbon, pyrolysis gas, and pyrolysis oil. The pyrolysis gas and pyrolysis oil may exit the pyrolysis reactor 500 as a pyrolysis vapor stream 170.

[0267]

[0273] Pyrolysis is a treatment process that includes the chemical and thermal decomposition of the introduced feed. All pyrolysis processes are generally characterized by a substantially oxygen-free reaction environment, but the pyrolysis process may be further defined, for example, by the pyrolysis reaction temperature in the reactor, the residence time in the pyrolysis reactor, the type of reactor, the pressure in the pyrolysis reactor, and the presence or absence of a pyrolysis catalyst.

[0268]

[0274] In one aspect or in combination with any aspect described herein, the pyrolysis reactor 510 may be, for example, a film reactor, a screw extruder, a tubular reactor, a tank, a stirred tank reactor, a riser reactor, a fixed bed reactor, a fluidized bed reactor, a rotary furnace, a vacuum furnace, a microwave oven, or an autoclave. The pyrolysis reactor 510 includes film reactors such as falling film reactors and rising film reactors.

[0269]

[0275] In one embodiment or in combination with any embodiment described herein, the pyrolysis reaction may include heating and converting the raw materials in a substantially oxygen-free atmosphere or in an atmosphere containing less oxygen than the ambient atmosphere. For example, the atmosphere inside the pyrolysis reactor 510 may contain 5% or less, 4% or less, 3% or less, 2% or less, 1% or less, or 0.5% or less of oxygen gas based on the internal volume of the reactor 510.

[0270]

[0276] In one embodiment or in combination with any embodiment described herein, the flotation gas and / or feed gas may be used to introduce raw materials into the pyrolysis reactor 510 and / or to facilitate various reactions within the pyrolysis reactor 510. For example, the flotation gas and / or feed gas may include, essentially consist of, nitrogen, carbon dioxide, and / or steam. The flotation gas and / or feed gas may be added together with the waste plastic stream 116 before being introduced into the pyrolysis reactor 510 and / or added directly to the pyrolysis reactor 510. The flotation gas and / or feed gas may include steam and / or reducing gases such as hydrogen, carbon monoxide, and combinations thereof.

[0271]

[0277] Furthermore, the temperature inside the pyrolysis reactor 510 can be adjusted to promote the production of a specific final product. In one embodiment or in combination with any embodiment described herein, the pyrolysis temperature inside the pyrolysis reactor 510 may be at least 325°C, at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, at least 650°C, at least 675°C, at least 700°C, at least 725°C, at least 750°C, at least 775°C, or at least 800°C.

[0272]

[0278] Furthermore, or alternatively, the pyrolysis temperature in the pyrolysis reactor may be 1,100°C or lower, 1,050°C or lower, 1,000°C or lower, 950°C or lower, 900°C or lower, 850°C or lower, 800°C or lower, 750°C or lower, 700°C or lower, 650°C or lower, 600°C or lower, 550°C or lower, 525°C or lower, 500°C or lower, 475°C or lower, 450°C or lower, 425°C or lower, or 400°C or lower. More specifically, the pyrolysis temperature in the pyrolysis reactor may be in the range of 325-1,100°C, 350-900°C, 350-700°C, 350-550°C, 350-475°C, 425-1,100°C, 425-800°C, 500-1,100°C, 500-800°C, 600-1,100°C, 600-800°C, 650-1,000°C, or 650-800°C.

[0273]

[0279] In one embodiment or in combination with any embodiment described herein, the residence time of the raw materials in the pyrolysis reactor may be at least 0.1 seconds, at least 0.2 seconds, at least 0.3 seconds, at least 0.5 seconds, at least 1 second, at least 1.2 seconds, at least 1.3 seconds, at least 2 seconds, at least 3 seconds, or at least 4 seconds. Alternatively, the residence time of the raw materials in the pyrolysis reactor may be at least 1 minute, at least 2 minutes, at least 3 minutes, at least 4 minutes, at least 5 minutes, at least 6 minutes, at least 7 minutes, at least 8 minutes, at least 9 minutes, at least 10 minutes, at least 20 minutes, at least 30 minutes, at least 45 minutes, at least 60 minutes, at least 75 minutes, or at least 90 minutes. Furthermore or alternatively, the residence time of the raw materials in the pyrolysis reactor may be less than 6 hours, less than 5 hours, less than 4 hours, less than 3 hours, less than 2 hours, less than 1 hour, or less than 0.5 hours. Furthermore, the residence time of the raw materials in the pyrolysis reactor may be less than 100 seconds, less than 90 seconds, less than 80 seconds, less than 70 seconds, less than 60 seconds, less than 50 seconds, less than 40 seconds, less than 30 seconds, less than 20 seconds, less than 10 seconds, less than 9 seconds, less than 8 seconds, less than 7 seconds, less than 6 seconds, less than 5 seconds, less than 4 seconds, less than 3 seconds, less than 2 seconds, or less than 1 second. More specifically, the residence time of the raw materials in the pyrolysis reactor may be in the range of 0.1 to 10 seconds, 0.5 to 10 seconds, 30 minutes to 4 hours, 30 minutes to 3 hours, 1 hour to 3 hours, or 1 hour to 2 hours.

[0274]

[0280] In one embodiment or in combination with any embodiment described herein, the pressure inside the pyrolysis reactor is maintained at a pressure of at least 0.1 bar, at least 0.2 bar, or at least 0.3 bar, and / or 60 bar or less, 50 bar or less, 40 bar or less, 30 bar or less, 20 bar or less, 10 bar or less, 8 bar or less, 5 bar or less, 2 bar or less, 1.5 bar or less, or 1.1 bar or less. The pressure inside the pyrolysis reactor is maintained at atmospheric pressure, or within the range of 0.1 to 100 bar, 0.1 to 60 bar, 0.1 to 30 bar, 0.1 to 10 bar, 1.5 bar, 0.2 to 1.5 bar, or 0.3 to 1.1 bar. The pressure inside the pyrolysis reactor may be at least 10 bar, at least 20 bar, at least 30 bar, at least 40 bar, at least 50 bar, at least 60 bar, or at least 70 bar, and / or 100 bar or less, 95 bar or less, 90 bar or less, 85 bar or less, 80 bar or less, 75 bar or less, 70 bar or less, 65 bar or less, or 60 bar or less. The term "bar" as used herein means instrument pressure unless otherwise specified.

[0275]

[0281] In one embodiment or in combination with any embodiment described herein, the pyrolysis catalyst may be introduced into the feed stream 116 before being introduced into the pyrolysis reactor 510, and / or directly into the pyrolysis reactor 510. The catalyst may be homogeneous or heterogeneous and may include, for example, certain types of zeolites and other mesostructured catalysts. In some embodiments, the pyrolysis reaction may be uncatalyzed (e.g., carried out in the absence of a pyrolysis catalyst), and non-catalyzed heat-retaining inert additives such as sand may be included in the reactor 510 to facilitate heat transfer. A pyrolysis process that does not use a catalyst in this manner is sometimes called "pure pyrolysis."

[0276]

[0282] In one embodiment or in combination with any embodiment described herein, the pyrolysis reaction in the pyrolysis reactor 510 may occur substantially in the absence of a pyrolysis catalyst, at a temperature in the range of 350 to 600°C, a pressure in the range of 0.1 to 100 bar, and a residence time of 0.2 seconds to 4 hours, or 0.5 hours to 3 hours.

[0277]

[0283] In one embodiment or in combination with any embodiment described herein, the pyrolysis effluent or pyrolysis vapor may contain at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, or at least 75% by weight of pyrolysis oil, which may be in the form of vapor in the pyrolysis effluent when it leaves the heating reactor. However, these vapors may be subsequently condensed to obtain pyrolysis oil. Furthermore, or alternatively, the pyrolysis effluent or pyrolysis vapor may contain 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, or 25% by weight or less of pyrolysis oil, which may be in the form of vapor in the pyrolysis effluent when it leaves the heating reactor. The pyrolysis effluent or pyrolysis vapor may contain pyrolysis oil in the range of 20-99% by weight, 25-80% by weight, 30-85% by weight, 30-80% by weight, 30-75% by weight, 30-70% by weight, or 30-65% by weight, based on the total weight of the pyrolysis effluent or pyrolysis vapor.

[0278]

[0284] In one embodiment or in combination with any embodiment described herein, the pyrolysis effluent or pyrolysis vapor may contain at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, or at least 80% by weight of pyrolysis gas. Furthermore or instead, the pyrolysis effluent or pyrolysis vapor may contain 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, or 45% by weight or less of pyrolysis gas. The pyrolysis effluent may contain pyrolysis gases in amounts of 1-90% by weight, 10-85% by weight, 15-85% by weight, 20-80% by weight, 25-80% by weight, 30-75% by weight, or 35-75% by weight, based on the total weight of the flow.

[0279]

[0285] In one embodiment or in combination with any embodiment described herein, the pyrolysis effluent or pyrolysis vapor may contain at least 0.5% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 4% by weight, at least 5% by weight, at least 6% by weight, at least 7% by weight, at least 8% by weight, at least 9% by weight, or at least 10% by weight of pyrolysis residue. Furthermore or alternatively, the pyrolysis effluent may contain 60% by weight or less, 50% by weight or less, 40% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, or 5% by weight or less of pyrolysis residue. The pyrolysis effluent may contain pyrolysis residue in the range of 0.1 to 25% by weight, 1 to 15% by weight, 1 to 8% by weight, or 1 to 5% by weight, based on the total weight of the flow.

[0280]

[0286] In one embodiment or in combination with any embodiment described herein, the pyrolysis effluent or pyrolysis vapor may contain 15% by weight or less, 14% by weight or less, 13% by weight or less, 12% by weight or less, 11% by weight or less, 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less of free water. As used herein, "free water" means water that has been added to the pyrolysis apparatus in advance (as liquid or steam) and water produced in the pyrolysis apparatus.

[0281]

[0287] The pyrolysis systems described herein may produce pyrolysis effluents that can be separated into a pyrolysis oil stream 174, a pyrolysis gas stream 172, and a pyrolysis residue stream 176, each of which can be used directly in various downstream applications based on their formulation. Various properties and characteristics of the pyrolysis oil, pyrolysis gas, and pyrolysis residue are described below. Although all of the following properties and characteristics may be described separately, it is understood that each of the following properties and characteristics of the pyrolysis gas, pyrolysis oil, and / or pyrolysis residue is not mutually exclusive and may exist in any combination.

[0282]

[0288] In one embodiment or in combination with any embodiment described herein, the pyrolysis oil may primarily contain hydrocarbons having 4 to 30 carbon atoms per molecule (e.g., C4-C30 hydrocarbons). As used herein, the terms "Cx" or "Cx hydrocarbon" mean hydrocarbon compounds containing "x" total carbon atoms per molecule, and include all olefins, paraffins, aromatics, heterocyclics, and isomers having that number of carbon atoms. For example, n-butane, isobutane, and tert-butane, as well as butene and butadiene molecules, each fall under the general expression "C4". The pyrolysis oil may have a C4-C30 hydrocarbon content of at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight, on a total weight basis of the pyrolysis oil flow 174.

[0283]

[0289] In one embodiment or in combination with any embodiment described herein, the pyrolysis oil may mainly consist of C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons. For example, the pyrolysis oil may contain at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons, based on the total weight of the pyrolysis oil. The pyrolysis oil may also contain at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, or at least 55% by weight of C5-C12 hydrocarbons, based on the total weight of the pyrolysis oil. Furthermore, or alternatively, the pyrolysis oil may have a C5-C12 hydrocarbon content of 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, or 50% by weight or less. The pyrolysis oil may have a C5-C12 hydrocarbon content in the range of 10-95% by weight, 20-80% by weight, or 35-80% by weight, based on the total weight of the flow.

[0284]

[0290] In one embodiment or in combination with any embodiment described herein, the pyrolysis oil may contain varying amounts of olefins and aromatics, depending on the reactor conditions and whether or not a catalyst is used. The pyrolysis oil contains at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, or at least 40% by weight of olefins and / or aromatics, based on the total weight of the pyrolysis oil. Furthermore or alternatively, the pyrolysis oil may contain 90% or less by weight, 80% or less by weight, 70% or less by weight, 60% or less by weight, 50% or less by weight, 45% or less by weight, 40% or less by weight, 35% or less by weight, 30% or less by weight, 25% or less by weight, 20% or less by weight, 15% or less by weight, 10% or less by weight, 5% or less by weight, or 1% or less by weight of olefins and / or aromatics. As used herein, the term "aromatic compounds" means the total amount (by weight) of any compound containing an aromatic moiety, such as benzene, toluene, xylene, and styrene.

[0285]

[0291] In one embodiment or in combination with any embodiment described herein, the pyrolysis oil may have a paraffin (e.g., linear or branched alkane) content of at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, or at least 65% by weight, based on the total weight of the pyrolysis oil. Furthermore or alternatively, the pyrolysis oil may have a paraffin content of 99% by weight or less, 97% by weight or less, 95% by weight or less, 93% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, or 30% by weight or less. The pyrolysis oil may have a paraffin content in the range of 25-90% by weight, 35-90% by weight, or 50-80% by weight.

[0286]

[0292] In one embodiment or in combination with any embodiment described herein, the pyrolysis oil is at least 75°C, at least 80°C, at least 85°C, at least 90°C, at least 95°C, at least 100°C, at least 105°C, at least 110°C, or at least 115°C, and / or 250°C or less, 245°C or less, 240°C or less, 235°C or less, 230°C or less, 225°C or less, 220°C or less, 215°C or less, 210°C or less, 205°C or less, 200°C or less, 195°C or less, 190°C or less, 185°C or less, 180°C or less, 175°C or less, 170°C or less, or 165°C or less. The pyrolysis oil may have an intermediate boiling point of 160°C or lower, 155°C or lower, 150°C or lower, 145°C or lower, 140°C or lower, 135°C or lower, 130°C or lower, 125°C or lower, or 120°C or lower (measurements in accordance with ASTM D-5399). The pyrolysis oil may have a median boiling point in the range of 75 to 250°C, 90 to 225°C, or 115 to 190°C. As used herein, "median boiling point" means the median boiling temperature of the pyrolysis oil at which 50% by volume boils above the median boiling point and 50% by volume boils below the median boiling point.

[0287]

[0293] In one embodiment or in combination with any embodiment described herein, the boiling point range of the pyrolysis oil may be such that, as measured in accordance with ASTM D-5399, at least 90% of the pyrolysis oil boils at temperatures of 250°C, 280°C, 290°C, 300°C, or 310°C.

[0288]

[0294] Turning to the pyrolysis gas, the pyrolysis gas may have a methane content of at least 1 wt%, at least 2 wt%, at least 3 wt%, at least 4 wt%, at least 5 wt%, at least 6 wt%, at least 7 wt%, at least 8 wt%, at least 9 wt%, at least 10 wt%, at least 11 wt%, at least 12 wt%, at least 13 wt%, at least 14 wt%, or at least 15 wt%, and / or 50 wt% or less, 45 wt% or less, 40 wt% or less, 35 wt% or less, 30 wt% or less, 25 wt% or less, or 20 wt% or less, based on the total weight of the pyrolysis gas. In one aspect or in combination with any aspect described herein, the pyrolysis gas may have a methane content in the range of 1 to 50 wt%, 5 to 50 wt%, or 15 to 45 wt%.

[0289]

[0295] In one aspect or in combination with any aspect described herein, the pyrolysis gas has a C3 and / or C4 hydrocarbon content (including all hydrocarbons having 3 or 4 carbon atoms per molecule) of at least 5 wt%, at least 10 wt%, at least 15 wt%, at least 20 wt%, at least 25 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 55 wt%, or at least 60 wt%, and / or 99 wt% or less, 95 wt% or less, 90 wt% or less, 85 wt% or less, 80 wt% or less, 75 wt% or less, 70 wt% or less, or 65 wt% or less, based on the total weight of the pyrolysis gas. The pyrolysis gas may have a C3 hydrocarbon content, a C4 hydrocarbon content, or a total content of C3 and C4 hydrocarbons in the range of 10 to 90 wt%, 25 to 90 wt%, or 25 to 80 wt%.

[0290]

[0296] In one embodiment or in combination with any embodiment described herein, the pyrolysis gas may constitute at least 10% by weight, at least 20% by weight, at least 30% by weight, at least 40% by weight, or at least 50% by weight of the total emissions from the pyrolysis reactor, and the pyrolysis gas may have a combined content of at least 25% by weight, at least 40% by weight, at least 50% by weight, at least 60% by weight, at least 70% by weight, or at least 75% by weight of ethylene and propylene.

[0291]

[0297] Turning to the pyrolysis residue, in one embodiment or in combination with any embodiment described herein, the pyrolysis residue contains, on a basis of the total weight of the pyrolysis residue, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, or at least 85% by weight of C20+ hydrocarbons. As used herein, "C20+ hydrocarbons" means hydrocarbon compounds containing at least 20 total carbon atoms per molecule, and includes all olefins, paraffins, and isomers having that number of carbon atoms.

[0292]

[0298] In one embodiment or in combination with any embodiment described herein, the pyrolysis residue contains, on a basis of the total weight of the pyrolysis residue, at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of carbon-containing solids. Furthermore, or instead, the pyrolysis residue contains carbon-containing solids of 99% by weight or less, 90% by weight or less, 80% by weight or less, 70% by weight or less, 60% by weight or less, 50% by weight or less, 40% by weight or less, 30% by weight or less, 20% by weight or less, 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or more, 5% by weight or less, or 4% by weight or less. As used herein, “carbon-containing solids” means carbon-containing compositions of solids derived from pyrolysis at 25°C and 1 atm. Carbon-containing solids contain at least 20% by weight, at least 30% by weight, at least 40% by weight, at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, or at least 90% by weight of carbon in the total weight of the carbon-containing solids.

[0293]

[0299] In one embodiment or in combination with any embodiment described herein, at least a portion of the pyrolysis gas, pyrolysis oil, and pyrolysis residue may be sent to one or more of the other chemical processing equipment, such as the energy recovery equipment 80, the partial oxidation equipment 50, one or more of the other equipment 90 described above, and the cracking equipment 70. Depending on the embodiment, at least a portion of the pyrolysis gas stream 172 and / or at least a portion of the pyrolysis oil stream 174 may be introduced into the energy recovery equipment 80, the cracking equipment 70, the POX gasification equipment 50, and combinations thereof, while the pyrolysis residue stream 176 may be introduced into the POX gasification equipment 50 and / or the energy recovery equipment 80. Depending on the embodiment, at least a portion of the pyrolysis gas stream 172, the pyrolysis oil stream 174, and / or the pyrolysis residue stream 176 may be sent to one or more separation units (not shown in Figures 1a and 1b) to form a more refined stream of pyrolysis gas, pyrolysis oil, and / or pyrolysis residue, which may then be sent to an energy recovery unit 80, a cracking unit 70, and / or a POX gasification unit 50. Alternatively, all or part of the pyrolysis oil stream 176 may be mixed with a PO-enriched waste plastics stream 114 to provide a liquefied plastics stream that can be supplied to one or more downstream units as described herein.

[0294] cracking

[0300] In one embodiment or in combination with any embodiment described herein, at least a portion of one or more flows from the pyrolysis equipment 60, or one or more flows from one or more of the other equipment shown in Figures 1a and 1b, may be introduced into the cracking equipment 70. As used herein, the term “cracking” means breaking down complex organic molecules into simpler molecules by cleaving carbon-carbon bonds. A “cracking equipment” is equipment that includes all the instruments, lines, and control units necessary for cracking raw materials derived from waste plastics. A cracking equipment may include one or more cracking furnaces and a downstream separation section that includes equipment for treating the effluent from the cracking furnaces. As used herein, the terms “cracker” and “cracking” are used interchangeably.

[0295]

[0301] Next, turning to Figure 8a, we see a cracking facility 70 configured according to one or more embodiments of the present technology. Generally, the cracking facility 70 includes a cracking furnace 720 and a separation section 740 downstream of the cracking furnace 720 for separating the furnace effluent into various final products, such as a regenerated olefin (recycled olefin) stream 130. As shown in Figure 8a, at least a portion of the pyrolysis gas stream 172 and / or pyrolysis oil stream 174 from the pyrolysis facility 60 can be fed into the cracking facility 70. The pyrolysis oil stream 174 can be introduced into the inlet of the cracking furnace 720, and the pyrolysis gas stream 172 can be introduced at an upstream or downstream location of the furnace 720. As also shown in Figure 8a, a stream of paraffin 132 (e.g., ethane and / or propane) may be taken out of the separation section and may contain a regenerated paraffin (recycled paraffin). All or part of the paraffin may be recirculated to the inlet of the cracking furnace 720 via flow 134, as also shown in Figure 8a. When used, the pyrolysis oil flow, pyrolysis gas flow 172, and regenerated paraffin flow 174 may be combined with the cracker feed flow 136 as needed to form a feed flow 119 to the cracking equipment 720.

[0296]

[0302] In one embodiment or in combination with any embodiment described herein, the supply stream 119 to the cracking equipment 70 may include at least one of the following: (i) one or more solvolysis byproduct streams 110 as described above, (ii) a PO enrichment stream 114 of waste plastics, and (iii) a pyrolysis stream (e.g., pyrolysis gas 172 and / or pyrolysis oil 174). One or more of these streams may be introduced into the cracking equipment 70 continuously or intermittently. If there are multiple types of supply streams, each may be introduced separately, or all or some of the streams may be mixed to introduce a mixed stream into the cracking equipment 70. When mixing streams, this may be done continuously or in batches. One or more supply streams introduced into the cracking equipment 70 may be in the form of a stream that is mainly gaseous, a stream that is mainly liquid, or a combination thereof.

[0297]

[0303] As shown in Figure 8a, the pyrolysis gas stream 172 and / or the pyrolysis oil stream 174 may be introduced into the cracking equipment 70 together with the cracker feed material stream 136. Depending on the embodiment, the cracker feed stream 119 may contain, on a basis of the total weight of the stream 119, at least 1% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight of pyrolysis gas, pyrolysis oil, or a combination of pyrolysis gas and pyrolysis oil. Alternatively, or in addition, the cracker supply stream 119 may contain, on a basis of the total weight of the stream 119, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, or 20% by weight or less of pyrolysis gas, pyrolysis oil, or a combination of pyrolysis gas and pyrolysis oil, or these components may be contained in amounts ranging from 1 to 95% by weight, 5 to 90% by weight, or 10 to 85% by weight, on a basis of the total weight of the stream 119.

[0298]

[0304] Depending on the embodiment, the cracker supply stream 119 may be at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight. , and / or may include hydrocarbon feeds other than pyrolysis gases and pyrolysis oils in amounts of 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, or 20% by weight or less, or may include hydrocarbon feeds other than pyrolysis gases and pyrolysis oils in amounts of 5 to 95% by weight, 10 to 90% by weight, or 15 to 85% by weight based on the total weight of the cracker feed stream 119.

[0299]

[0305] In one embodiment or in combination with any embodiment described herein, the cracker feed stream 119 may include a composition mainly comprising C2-C4 hydrocarbons. As used herein, the term “mainly C2-C4 hydrocarbons” means a stream or composition containing at least 50% by weight of C2-C4 hydrocarbon components. Specific examples of C2-C4 hydrocarbon streams or compositions include propane, ethane, butane, and LPG. The cracker feed stream 119 may contain, on a basis of the total weight of the feed, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight, and / or 100% by weight or less, 99% by weight or less, 95% by weight or less, 92% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight or less of C2-C4 hydrocarbons or linear alkanes on a basis of the total weight of the feed. The cracker feed stream 119 may contain mainly propane, mainly ethane, mainly butane, or a combination of two or more of these components.

[0300]

[0306] In one embodiment or in combination with any embodiment described herein, the cracker feed stream 119 may include a composition mainly comprising C5-C22 hydrocarbons. As used herein, “mainly C5-C22 hydrocarbons” means a stream or composition containing at least 50% by weight of C5-C22 hydrocarbon components. Examples include gasoline, naphtha, middle distillates, diesel fuel, kerosene, and the like.

[0301]

[0307] In one embodiment or in combination with any embodiment described herein, the cracker supply flow 119 is at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, and less It may also contain 90% by weight, or at least 95% by weight, and / or 100% by weight or less, 99% by weight or less, 95% by weight or less, 92% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, or 60% by weight or less of C5-C22 or C5-C20 hydrocarbons, or it may contain C5-C22 in amounts ranging from 20-100% by weight, 25-95% by weight, or 30-85% by weight based on the total weight of the flow.

[0302]

[0308] In one embodiment or in combination with any embodiment described herein, the cracker feed stream 119 may have a content of at least 0.5% by weight, at least 1% by weight, at least 2% by weight, or at least 5% by weight, and / or 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 8% by weight or less, 15% by weight or less, 12% by weight or less, 10% by weight or less, 5% by weight or less, or 3% by weight or less of C15 and heavier (C15+) based on the total weight of the feed stream, or it may be in the range of 0.5 to 40% by weight, 1 to 35% by weight, or 2 to 30% by weight based on the total weight of the flow.

[0303]

[0309] In one embodiment or in combination with any embodiment described herein, the feed stream introduced into the cracking furnace may include vacuum gas oil (VGO), hydrogenated vacuum gas oil (HVGO), or atmospheric pressure gas oil (AGO). The cracker feed stream 119 is composed of at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, and at least It may also contain 85% by weight, or at least 90% by weight, and / or at least one gas oil in amounts of 99% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, or 50% by weight or less, or it may be present in amounts ranging from 5 to 99% by weight, 10 to 90% by weight, 15 to 85% by weight, or 5 to 50% by weight based on the total weight of flow 119.

[0304]

[0310] As shown in Figure 8a, the cracker feed stream 119 is introduced into the cracking furnace 720. Turning to Figure 8b, a schematic diagram of the cracking furnace 720 suitable for use in the chemical regeneration facility and / or cracking equipment described herein is shown. As shown in Figure 8b, the cracking furnace 720 may include a convection section 746, a radiant section 748, and a cross section 750 located between the convection section 746 and the radiant section 748. The convection section 746 is part of the furnace that receives heat from the hot flue gas and includes a row of tubes or coils 752 through which the cracker stream passes. The convection section 746 heats the cracker stream by convection from the hot flue gas passing through it. Although Figure 8b shows a horizontally arranged convection tube 752a and a vertically arranged radiant tube 752b, it goes without saying that the tubes can be arranged in any suitable configuration. For example, the convection tube 752a may be vertical. The radiating tube 752b may be horizontal. Furthermore, although shown as a single tube, the cracking furnace 720 may include one or more tubes or coils, which may include at least one branched tube, bent tube, U-tube, elbow tube, or a combination thereof. If multiple tubes or coils are present, they may be arranged in parallel and / or in series.

[0305]

[0311] The radiant section 748 is the part of the furnace 720 where heat is transferred to the heating tubes primarily by radiation from the high-temperature gas. The radiant section 748 also includes several burners 756 that introduce heat to the lower part of the furnace 720. The furnace 720 includes a firebox 754 that surrounds and houses the tubes 752b within the radiant section 748, and the burners 756 are positioned within it. The crossover section 750 includes piping that connects the convection section 746 and the radiant section 748, allowing the heated cracker flow to move from one part to the other, or from inside to outside the furnace 720.

[0306]

[0312] As the high-temperature combustion gases rise upward through the furnace exhaust stack, the gases pass through a convection section 746, where at least some of the waste heat is recovered and used to heat the cracker flow passing through the convection section 746. The cracking furnace 720 may have a single convection (preheating) section and a single radiant section, and in other embodiments, the furnace may include two or more radiant sections sharing a common convection section. At least one induced draft (ID) fan 760 near the exhaust stack can control the flow and heating characteristics of the high-temperature flue gases passing through the furnace 720, and one or more heat exchangers 761 may be used to cool the furnace wastewater. To cool the decomposed olefin-containing effluent 125, liquid cooling (not shown) may be used in addition to, or instead of, the exchanger 761 at the furnace outlet shown in Figure 8b (e.g., a transport pipe heat exchanger i.e., TLE).

[0307]

[0313] In one or more embodiments, the pyrolysis gas may be introduced into the inlet of the cracking furnace, or all or part of the pyrolysis gas may be introduced upstream of the separation section of the cracking equipment or at a location within that section downstream of the furnace outlet. When introduced into the separation section or upstream of the separation section, the pyrolysis gas can be introduced upstream of the final stage of compression or before the inlet of at least one fractionation column in the fractionation section of the separation section.

[0308]

[0314] Before entering the cracking equipment 70, in one or more embodiments, the stream of raw pyrolysis gas 172 from the pyrolysis equipment may undergo one or more separation steps to remove one or more components from the stream. Examples of such components may include, but are not limited to, halogens, aldehydes, oxygen-containing compounds, nitrogen-containing compounds, sulfur-containing compounds, carbon dioxide, water, vaporized metals, and combinations thereof. In one or more embodiments, the pyrolysis gas stream 172 introduced into the cracking equipment 70 contains, on a basis of the total weight of the pyrolysis gas stream 172, at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, at least 2% by weight, at least 2.5% by weight, at least 3% by weight, at least 3.5% by weight, at least 4% by weight, at least 4.5% by weight, or at least 5% by weight, and / or 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less of one or more aldehyde components.

[0309]

[0315] In one embodiment or in combination with any embodiment described herein, the cracking equipment 70 may include a single cracking furnace, or it may have at least two, or at least three, or at least four, or at least five, or at least six, or at least seven, or at least eight, or more parallel operating cracking furnaces. Any one or each of the furnaces may be a gas cracker, or a liquid cracker, or a split furnace. A furnace may be a gas cracker that receives a cracker feed stream from the furnace, or from at least one coil in the furnace, or from at least one tube in the furnace, containing at least 50% by weight, at least 75% by weight, at least 85% by weight, or at least 90% by weight of ethane, propane, LPG, or a combination thereof, on a weight basis of the total cracker feed to the furnace.

[0310]

[0316] In one embodiment or in combination with any embodiment described herein, the cracking furnace 720 may be a liquid or naphtha cracker that accepts a cracker feed stream containing a liquid hydrocarbon having at least 50% by weight, at least 75% by weight, or at least 85% by weight of C5-C22 carbon atoms (measured at 25°C and 1 atm).

[0311]

[0317] In one embodiment or in combination with any embodiment described herein, the cracker feed stream 119 can be broken up in a gas furnace. The gas furnace is a furnace ("gas coil") having at least one coil at the inlet of a convection section, at the inlet of this coil receiving (or operating to receive, or configured to receive) a feed mainly of the vapor phase (where 50% or more of the weight of the feed is vapor). The gas coil may receive mainly C2-C4 feed material or mainly C2-C3 feed material at the inlet of the coil in the convection section, or instead, the gas coil has at least one coil that receives more than 50% by weight of ethane, more than 50% by weight of propane, and / or more than 50% by weight of LPG, on a weight basis of the cracker feed to the coil or on a weight basis of the cracker feed to the convection section, or in either of these cases, receiving at least 60% by weight, or at least 70% by weight, or at least 80% by weight of ethane, propane, or LPG.

[0312]

[0318] A gas furnace may have two or more gas coils. In one embodiment or in combination with any embodiment described herein, at least 25%, 50%, 60%, or all of the coils in the convection compartment or convection box of the furnace are gas coils. The gas coils receive a gas phase feed at the coil inlet located at the inlet of the convection section, in which at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, at least 97% by weight, at least 98% by weight, at least 99% by weight, at least 99.5% by weight, or at least 99.9% by weight of the feed is vapor.

[0313]

[0319] In one embodiment or in combination with any embodiment described herein, the feed flow can be split in a split furnace. The split furnace is a type of gas furnace. The split furnace houses at least one gas coil and at least one liquid coil in the same furnace, or in the same convection compartment, or in the same convection box. The liquid coil is a coil that receives a feed that is mainly liquid phase (at least 50% of the feed's weight is liquid) at the coil inlet located at the inlet of the convection compartment ("liquid coil").

[0314]

[0320] In one embodiment or in combination with any embodiment described herein, the cracker supply stream 119 can be decomposed by a hot gas cracker.

[0321] In one embodiment or in combination with any embodiment described herein, the cracker feed stream 119 can be decomposed in a hot steam gas cracker in the presence of water vapor. Water vapor cracking means cracking (decomposing) hydrocarbons at high temperatures in the presence of water vapor. If present, water vapor may be introduced from line 121 shown in Figure 8b.

[0315]

[0322] In one embodiment or in combination with any embodiment described herein, if two or more flows from the chemical regeneration facility 10 shown in Figures 1a and 1b are mixed with another flow from the equipment 10 to form a cracker feed flow 119, such mixed flow may be generated upstream of or inside the cracking furnace 720. Alternatively, different feed flows may be introduced into the furnace 720 separately and passed through part or all of the furnace 720 simultaneously, while being isolated from each other by supplying them to separate pipes (e.g., split furnaces) within the same furnace 720. Alternatively, at least one or more flows from the chemical regeneration facility may be introduced into the cracking equipment downstream of the cracking furnace but upstream of one or more pieces of equipment within the separation equipment.

[0316]

[0323] When two or more flows from a chemical regeneration facility are mixed with another flow to form a cracker feed flow, such a mixed flow may be generated upstream of or within the cracking furnace. Alternatively, the different feed flows may be introduced into the furnace separately and passed through part or all of the furnace simultaneously, separated from each other by being supplied to separate pipes (e.g., split furnaces) within the same furnace. Alternatively, at least one or more flows from the chemical regeneration facility may be introduced into the cracking equipment downstream of the cracking furnace but upstream of one or more pieces of equipment within the separation equipment.

[0317]

[0324] The heated cracker flow 119 then passes through the cracking furnace 720, where the hydrocarbon components in the flow are thermally decomposed to form lighter hydrocarbons, including olefins such as ethylene, propylene, and / or butadiene. The residence time of the cracker flow in the furnace 720 may be at least 0.15 seconds, at least 0.2 seconds, at least 0.25 seconds, at least 0.3 seconds, at least 0.35 seconds, at least 0.4 seconds, or at least 0.45 seconds, and / or 2 seconds or less, 1.75 seconds or less, 1.5 seconds or less, 1.25 seconds or less, 1 second or less, 0.9 seconds or less, 0.8 seconds or less, 0.75 seconds or less, 0.7 seconds or less, 0.65 seconds or less, 0.6 seconds or less, or 0.5 seconds or less, or in the range of 0.15 to 2 seconds, 0.20 to 1.75 seconds, or 0.25 to 1.5 seconds.

[0318]

[0325] The temperature of the decomposed olefin-containing spill 125 drawn out from the furnace outlet is at least 640°C, at least 650°C, at least 660°C, at least 670°C, at least 680°C, at least 690°C, at least 700°C, at least 720°C, at least 730°C, at least 740°C, at least 750°C, at least 760°C, at least 770°C, at least 780°C, at least 790°C, at least 800°C, at least 810°C, or At least 820°C, and / or 1000°C or less, 990°C or less, 980°C or less, 970°C or less, 960°C or less, 950°C or less, 940°C or less, 930°C or less, 920°C or less, 910°C or less, 900°C or less, 890°C or less, 880°C or less, 875°C or less, 870°C or less, 860°C or less, 850°C or less, 840°C or less, or 830°C or less, or in the range of 730 to 900°C, 750 to 875°C, or 750 to 850°C.

[0319]

[0326] In one embodiment or in combination with any embodiment described herein, the yield of the olefin (ethylene, propylene, butadiene, or a combination thereof) may be at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, or at least 80%. As used herein, the term “yield” means (mass of product produced from mass of raw materials / mass of raw materials) × 100%. The olefin-containing spillage contains at least 30% by weight, at least 40% by weight, at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 97% by weight, or at least 99% by weight of ethylene, propylene, or ethylene and propylene, based on the total weight of the spillage.

[0320]

[0327] In one embodiment or in combination with any embodiment described herein, the olefin-containing spillage 125 may contain at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, or at least 90% by weight of C2-C4 olefins. The spillage 125 may contain mainly ethylene, mainly propylene, or mainly ethylene and propylene, on a total weight basis of the olefin-containing spillage 125. The weight ratio of ethylene to propylene in the olefin-containing spill logistics 125 may be at least 0.2:1, at least 0.3:1, at least 0.4:1, at least 0.5:1, at least 0.6:1, at least 0.7:1, at least 0.8:1, at least 0.9:1, at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.3:1, at least 1.4:1, at least 1.5:1, at least 1.6:1, at least 1.7:1, at least 1.8:1, at least 1.9:1, or at least 2:1 and / or 3:1 or less, 2.9:1 or less, 2.8:1 or less, 2.7:1 or less, 2.5:1 or less, 2.3:1 or less, 2.2:1 or less, 2.1:1 or less, 2:1 or less, 1.7:1 or less, 1.5:1 or less, or 1.25:1 or less.

[0321]

[0328] Turning back to Figure 8a, in one embodiment or in combination with any embodiment described herein, when introduced into the cracking equipment 70, the pyrolysis gas 172 may be introduced into the inlet of the cracking furnace 720, or all or part of the pyrolysis gas may be introduced upstream of the separation section 740 of the cracking equipment 70 or at a location within that section downstream of the furnace outlet. When introduced into or upstream of the separation section 740, the pyrolysis gas may be introduced upstream of the final stage of compression or before the inlet of at least one fractionation tower in the fractionation section of the separation section 740.

[0322]

[0329] Before entering the cracking equipment 70, the raw pyrolysis gas stream from the pyrolysis equipment may be subjected to one or more separation steps to remove one or more components from the stream, in one embodiment or in combination with any embodiment described herein. Examples of such components include, but are not limited to, halogens, aldehydes, oxygen-containing compounds, nitrogen-containing compounds, sulfur-containing compounds, carbon dioxide, water, vaporized metals, and combinations thereof. The pyrolysis gas flow 172 introduced into the cracking equipment 70 may contain, based on the total weight of the pyrolysis gas flow 172, at least 0.1% by weight, at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, at least 2% by weight, at least 2.5% by weight, at least 3% by weight, at least 3.5% by weight, at least 4% by weight, at least 4.5% by weight, or at least 5% by weight, and / or 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less of one or more aldehyde components.

[0323]

[0330] In one embodiment or in combination with any embodiment described herein, the total ethylene content of the pyrolysis gas flow 172 may be at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, or at least 30% by weight, and / or 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, or 35% by weight or less. Alternatively, or in addition to the above, the total propylene content of the pyrolysis gas stream 172 may be at least 1% by weight, at least 2% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, or at least 30% by weight, and / or 60% by weight or less, 55% by weight or less, 50% by weight or less, 45% by weight or less, 40% by weight or less, or 35% by weight or less. The total amount of ethylene and propylene in the pyrolysis gas flow 172 may be at least 2% by weight, at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, or at least 45% by weight, and / or 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 50% by weight or less, or 45% by weight or less, based on the total weight of the flow.

[0324]

[0331] As the olefin-containing effluent 125 exits the cracking furnace, it may be rapidly cooled (e.g., quenched) to prevent the production of large amounts of undesirable by-products and minimize contamination of downstream equipment. In one embodiment or in combination with any embodiment described herein, the temperature of the olefin-containing effluent from the furnace may be reduced during the quenching or cooling process by only 35-485°C, 35-375°C, or 90-550°C, or down to 500-760°C.

[0325]

[0332] The resulting cooled effluent can then be separated in a gas-liquid separator, and the vapor can be compressed, for example, in a gas compressor having 1 to 5 compression stages with arbitrary interstage cooling and liquid removal. The pressure of the gas flow at the outlet of the first set of compression stages is in the range of 7 to 20 barg (gauge pressure), 8.5 to 18 barg, or 9.5 to 14 barg. The resulting compressed flow is then treated with an acidic gas remover to remove acidic gases, including halogens, CO, CO2, and H2S. Examples of acidic gas removers include, but are not limited to, caustic soda and various types of amines. In one embodiment or in combination with any embodiment described herein, a single contactor may be used, and in other embodiments, a two-tower absorber-stripper configuration may be employed.

[0326]

[0333] The treated compressed olefin-containing stream may then be further compressed in another compressor, with interstage cooling and liquid separation if necessary. This results in a compressed stream with pressures in the range of 20–50 barg, 25–45 barg, or 30–40 barg. Any suitable desiccation method can be used, for example, including molecular sieves or other similar processing steps. This stream can then be sent to a fractionation section, where the olefin and other components can be separated into various high-purity product streams or intermediate streams. Depending on the embodiment, all or part of the pyrolysis gas may be introduced before and / or after one or more stages of the second compressor. Similarly, the pressure of the pyrolysis gas is within 20 psi, 50 psi, 100 psi, or 150 psi of the pressure of the stream into which it is mixed.

[0327]

[0334] In one embodiment or in combination with any embodiment described herein, the feed flow from the quenching section may be introduced into at least one column in the fractionation section of the separation section. As used herein, the term “fractionation” refers to a general process of separating two or more substances having different boiling points. Examples of apparatuses and processes that utilize fractionation include, but are not limited to, distillation, rectification, stripping, and gas-liquid separation (single stage).

[0328]

[0335] In one embodiment or in combination with any embodiment described herein, the fractionation section of the cracking equipment may include one or more demethane units, ethane units, propane units, ethylene splitters, propylene splitters, butane units, and combinations thereof. As used herein, the term “demethane unit” means a tower whose light main component is methane. Similarly, “ethane unit” and “propane unit” mean towers whose light main components are ethane and propane, respectively.

[0329]

[0336] Any suitable arrangement of the column may be used so that the fractionation section provides at least one olefin product stream and at least one paraffin stream. In one embodiment or any combination of embodiments described herein, the fractionation section can provide at least two olefin streams, such as ethylene and propylene, and at least two paraffin streams, such as ethane and propane, as well as additional streams, for example, methane and light components and butane and heavy components.

[0330]

[0337] In one embodiment or in combination with any embodiment described herein, the olefin stream removed from the separation unit may contain, on a basis of the total weight of the olefin stream, at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, or at least 95% by weight, and / or 100% by weight or less, 99% by weight or less, 97% by weight or less, 95% by weight or less, 90% by weight or less, 85% by weight or less, or 80% by weight or less of olefin. The olefin may be mainly ethylene or mainly propylene. The olefin stream may contain, on a basis of the total weight of olefins in the olefin stream, at least 50% by weight, at least 55% by weight, at least 60% by weight, at l...

Claims

1. A method for processing waste plastics, (a) A process of combining a stream of waste plastics, including polyethylene terephthalate (PET) and at least one non-PET plastic, with a solvent in a solvolysis dissolution tank within a solvolysis equipment, to provide a stream that is mainly liquid. (b) A step of adding a catalyst containing lithium, manganese, or a combination thereof to the flow which is mainly liquid, and (c) A step of depolymerizing at least a portion of the PET in a solvolysis reactor to form a stream of major terephthalyl, major glycol, and at least one byproduct. Includes, The solvent is methanol. The aforementioned non-PET plastic contains polyvinyl chloride in an amount ranging from 0.01 to 10% by weight, based on the weight of the waste plastic flow. Methods for disposing of waste plastic.

2. A method for processing waste plastics, (a) A process of combining a stream of waste plastics, including polyethylene terephthalate (PET) and at least one non-PET plastic, with a solvent in a solvolysis dissolution tank within a solvolysis equipment, to provide a stream that is mainly liquid. (b) A step of transferring at least a portion of the flow, which is mainly liquid, to a solvolysis reactor. (c) A step of adding a catalyst containing lithium, manganese, sodium, potassium, or a combination thereof to the waste plastic, the solvent, or at least one of the flow which is mainly liquid, and (d) A step of depolymerizing at least a portion of the PET in the solvolysis reactor to form a stream of major terephthalyl, major glycol, and at least one byproduct. Includes, The solvent is methanol. The aforementioned non-PET plastic contains polyvinyl chloride in an amount ranging from 0.01 to 10% by weight, based on the weight of the waste plastic flow. Methods for disposing of waste plastic.

3. A method for processing waste plastics, (a) A process of subjecting a stream of waste plastics containing polyethylene terephthalate (PET) to solvolysis in a solvolysis facility, and carrying out at least a portion of this process in the presence of at least one solvolysis catalyst including manganese, lithium, or a combination thereof, to produce a major glycol, a major terephthalyl, and at least one solvolysis byproduct, and (b) A step of introducing at least a portion of the solvolysis byproduct into at least one of the following: (i) a pyrolysis unit, (ii) a cracking unit, (iii) a partial oxidation (POX) gasification unit, (iv) an energy recovery unit, and (v) a liquefaction unit. Includes, The solvent in the solvolysis described above is methanol. The aforementioned waste plastic stream contains polyvinyl chloride in an amount ranging from 0.01% to 10% by weight, based on the weight of the waste plastic stream. Methods for disposing of waste plastic.

4. The method of claim 2, wherein step (c) comprises adding the catalyst together with the waste plastic, or step (c) comprises adding the catalyst together with the solvent, or step (c) comprises adding the catalyst to the flow which is mainly liquid during at least a portion of the transfer step of step (b).

5. The method according to claim 1 or 2, wherein the catalyst is present in an amount ranging from 25 to 1,000 ppm by weight, based on the total weight of the flow, which is mainly liquid.

6. The method of claim 5, wherein the catalyst comprises a sodium-containing base, a potassium-containing base, or a combination thereof.

7. The method according to any one of claims 1 to 4, wherein the catalyst comprises manganese.

8. The method of claim 1 or 2, wherein the catalyst comprises 100 to 600 ppm by weight of manganese acetate and 100 to 350 ppm by weight of sodium hydroxide, based on the total weight of the flow, which is mainly liquid.

9. The method of claim 1 or 2, wherein the catalyst comprises zinc, tin, and titanium in an amount of 250 ppm by weight or less, based on the total weight of the flow, which is mainly liquid.

10. The method according to claim 1 or 2, wherein the non-PET plastic contains polyolefin (PO) in an amount of 10 to 80% by weight, based on the total weight of the waste plastic.

11. The method according to any one of claims 1 to 4, wherein the PET is present in the waste plastic in an amount of at least 25% by weight based on the total weight of the waste plastic.

12. The method of claim 1 or 2, further comprising the step of introducing at least a portion of the byproduct stream into at least one of (i) a pyrolysis unit, (ii) a cracking unit, (iii) a partial oxidation (POX) gasification unit, (iv) an energy recovery unit, and (v) a liquefaction unit.

13. The method according to any one of claim 3, claim 7 relating to claim 3, or claim 11 relating to claim 3, wherein the solvolysis equipment is jointly installed with at least one of (i) the partial oxidation (POX) gasification equipment, (ii) the pyrolysis equipment, (iii) the cracking equipment, (iv) the energy recovery equipment, and (v) the liquefaction compartment.

14. The method according to any one of claims 1 to 4, wherein the solvolysis apparatus is operated continuously and has a feed rate of at least 500 pounds (227 kg) per hour on an annual average.

15. The method of claim 1 or 2, wherein the non-PET plastic contains polyolefin in an amount ranging from 10 to 80% by weight on a weight basis of the flow, or the PET is present in an amount ranging from 5 to 95% by weight on a weight basis of the flow.

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